Spray-drying apparatus and methods of using the same

ABSTRACT

A spray-drying apparatus includes a drying chamber that has a first end, a second end, and at least one side wall extending between the first and second ends to define an interior of the drying chamber having a center axis. A nozzle can be positioned at the first end of the drying chamber and be configured to atomize liquid and spray the atomized liquid into the interior of the drying chamber at a maximum spray pattern angle relative to the center axis. A heating device can be provided to heat the liquid prior to introduction into the drying chamber.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 13/820,494, filed Mar. 1, 2013, which is the U.S. National Stage of International Application No. PCT/US2011/050218, filed Sep. 1, 2011, published in English under PCT Article 21(2), which claims the benefit of and priority to U.S. Provisional Patent Application No. 61/380,103 filed on Sep. 3, 2010, and U.S. Provisional Patent Application No. 61/386,316 filed on Sep. 24, 2010, each of which are incorporated herein in their entirety by reference.

FIELD

The present disclosure is directed to novel spray-drying apparatuses and methods of using the same.

BACKGROUND

The use of spray drying to produce powders from fluid feed stocks is well known, with applications ranging from powdered milk to bulk chemicals and pharmaceuticals. A typical spray-drying apparatus comprises a drying chamber, an atomizing means for atomizing a solvent-containing feed into the drying chamber, a drying gas that flows into the drying chamber to remove solvent from the atomized solvent-containing feed, and a product collection means located downstream of the drying chamber.

The use of spray drying to form solid amorphous dispersions of drugs or active agents and concentration-enhancing polymers is also known. When it is desired to form a spray-dried product in which the drug or active agent is amorphous, it is desirable to have the active agent fully dissolved in the spray solution when it is atomized into droplets. Specifically, when it is desired to form a spray-dried product in which the amorphous active agent is dispersed in one or more other materials, termed matrix material, it is generally desired to have at least a part and often all of the matrix material also dissolved in the spray solution. In such cases, the throughput of a conventional spray-drying process is often limited by the amount of active agent and matrix material that can be dissolved in the spray solution. It is generally known that the solubility of many substances, such as active agents and matrix materials, often increases as the temperature of the solvent is increased. However, industry avoids using elevated temperatures when using organic solvents, due to the inherent dangers and safety concerns when processing organic solvents, which are often flammable at high temperatures. In addition, conventional spray-drying processes avoid use of elevated temperatures out of concern for the thermal stability of the active agent and matrix material—degradation of the active agent and/or the matrix material can lead to unwanted breakdown products in the particles produced.

Because of this, conventional spray-drying solutions are generally kept at or near room temperature when entering the spray nozzle. This limits the throughput of the process due to the often low solubility of active agents and matrix materials in the solvents used. In addition, when the solubility of the active agent in the spray solution is low, the active agent is often dissolved to near its solubility limit to achieve as high a throughput as possible. The spray-dried products obtained from such solutions are often not homogeneous. Finally, conventional spray-dried processes often produce products that suffer from not being homogeneous because the rate of solvent removal is not sufficiently fast, and broad ranges of particle sizes are produced because the atomization means produces a wide range of droplet sizes.

SUMMARY

In one embodiment, a spray-drying apparatus is provided. The apparatus includes a drying-gas conduit and a drying chamber having a first end, second end, and at least one side wall extending between the first and second ends to define an interior of the drying chamber having a central axis. A nozzle can be positioned at the first end of the drying chamber. The nozzle can be configured to atomize a liquid and spray the atomized liquid into the interior of the drying chamber. The drying-gas conduit is in fluid communication with the drying chamber, and is configured to direct a flow of drying gas into the drying chamber. At least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from the center axis at a first angle relative to the center axis, the first angle being at least 5 degrees but less than 45 degrees. A ratio of the length between the first and second ends to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1.

In one embodiment, a spray-drying apparatus is provided. The apparatus includes a drying-gas conduit and a drying chamber having a first end, second end, and at least one side wall extending between the first and second ends to define an interior of the drying chamber having a central axis. A nozzle can be positioned at the first end of the drying chamber. The nozzle can be configured to atomize a liquid and spray the atomized liquid into the interior of the drying chamber. The drying-gas conduit is in fluid communication with the drying chamber, and is configured to direct a flow of drying gas to enter the drying chamber in substantially parallel flow. At least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from the center axis at a first angle relative to the center axis, the first angle being at least 5 degrees but less than 45 degrees. A ratio of the length between the first and second ends to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1.

In certain embodiments, the drying gas entering the drying chamber satisfies at least one of (a) the velocity vector of the drying gas averaged over the opposing internal surfaces of the interior of the drying chamber is essentially parallel to the center axis of the drying chamber and is substantially towards the second end of the drying chamber; and (b) circulation cells near the first end of the drying chamber in the vicinity of the nozzle have diameters of less than 20% of the maximum width between opposing internal surfaces of the interior of the drying chamber. In certain embodiments, the drying gas entering the drying chamber satisfies both (a) and (b).

In certain embodiments, the walls of the drying gas conduit are generally parallel to the walls of the drying chamber.

In certain embodiments, the ratio of the length between the first and second ends to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 6 to 1.

In certain embodiments, a ratio of the maximum width to the width at the second end of the drying chamber interior is less than 3 to 1.

In certain embodiments, the nozzle is configured to atomize a liquid into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 45 degrees.

In certain embodiments, the first angle is at least 5 degrees but less than 30 degrees relative to the center axis. In certain embodiments, the nozzle is configured to atomize a liquid into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 30 degrees.

In certain embodiments, the first angle is at least 5 degrees but less than 20 degrees relative to the center axis. In certain embodiments, the nozzle is configured to atomize a liquid into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 20 degrees. In certain embodiments, the first angle is at least 10 degrees but less than 20 degrees relative to the center axis.

In certain embodiments, the at least one side wall of the drying chamber further comprises a second tapered portion at the second end, and the second tapered portion is narrowest at the second end and widest at a distance furthest from the second end.

In certain embodiments, the at least one side wall of the drying chamber further comprises a cylindrical portion of generally constant width located between the first and second tapered portions. In certain embodiments, the at least one side wall of the drying chamber has a generally circular cross section at each point along the center axis between the first end and the second end.

In certain embodiments, the atomized liquid comprises at least one active agent and at least one excipient. In certain embodiments, the atomized liquid comprises an active agent and at least one excipient in a solvent.

In certain embodiments, the atomized liquid can form particles that have a mass median aerodynamic diameter of less than 50 microns. In some embodiments, the particles have a mass median aerodynamic diameter of less than 20 microns. In some embodiments the particles can have a mass median aerodynamic diameter of less than 10 microns. In yet other embodiments, the particles can have a mass median aerodynamic diameter of less than 5 microns. In some embodiments, the particles can be inhalable particles.

In another embodiment, a method of spray drying is provided. The method can include forming a plurality of particles by atomizing a spray solution using a nozzle positioned at the first end of the drying chamber. The drying chamber comprises a second end and at least one side wall extending between the first and second ends to define an interior of the drying chamber having a center axis. At least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from a center axis of the drying chamber at a first angle relative to the center axis. The first angle can be at least 5 degrees but less than 45 degrees. A ratio of the length between the first and second ends to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1. The atomized spray solution is delivered into the drying chamber and a flow of drying gas is delivered into the drying chamber to at least partially dry the atomized spray solution to form a plurality of particles. The plurality of particles are directed out of the drying chamber.

In another embodiment, a method of spray drying is provided. The method can include forming a plurality of particles by atomizing a spray solution using a nozzle positioned at the first end of the drying chamber. The drying chamber comprises a second end and at least one side wall extending between the first and second ends to define an interior of the drying chamber having a center axis. At least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from a center axis of the drying chamber at a first angle relative to the center axis. The first angle can be at least 5 degrees but less than 45 degrees. A ratio of the length between the first and second ends to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1. The atomized spray solution is delivered into the drying chamber and a flow of drying gas is delivered into the drying chamber in substantially parallel flow to at least partially dry the atomized spray solution to form a plurality of particles. The plurality of particles are directed out of the drying chamber.

In some embodiments, the atomized spray solution can be delivered into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 45 degrees. In some embodiments, the atomized spray solution is delivered into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 30 degrees. In some embodiments, the atomized spray solution is delivered into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 20 degrees.

In some embodiments, the first angle is at least 5 degrees but less than 30 degrees relative to the center axis. In other embodiments, the first angle is at least 5 degrees but less than 20 degrees relative to the center axis.

In other embodiments, the spray solution comprises at least one excipient. In yet other embodiments, the particles formed in the drying chamber have a mass median aerodynamic diameter of less than 10 microns. In some embodiments, the particles can be inhalable particles.

In other embodiments, the particles can have a mean particle residence time of less than 10 seconds, or in other embodiments, less than 8 seconds, less than 5 seconds, or less than 3 seconds.

In another embodiment, a process for increasing the throughput of a spray drier comprises (a) delivering a spray solution comprising an active agent and a matrix material in an organic solvent to a spray-drying apparatus, (b) atomizing the spray solution into droplets within the spray-drying apparatus to remove at least a portion of the organic solvent from the droplets to form a plurality of particles, and (c) collecting the particles. The spray solution is formed by forming a feed suspension comprising the active agent, the matrix material, and the organic solvent, wherein the feed suspension is at a temperature T₁, and directing the feed suspension to a heat exchanger, thereby increasing the temperature of the feed suspension to a temperature T₂, wherein (i) temperature T₂ is greater than temperature T₁, and (ii) the spray solution is at a pressure that is greater than the vapor pressure of the solvent at temperature T₂, such that substantially all of the active agent in the spray solution and at least a portion of the matrix material are soluble in the solvent at temperature T₂.

In one embodiment, temperature T₂ is greater than the ambient-pressure boiling point of the organic solvent.

In another embodiment, the nozzle used for atomization of the spray solution is a pressure nozzle. In another embodiment, the nozzle used for atomization of the spray solution in the spray-drying apparatus is a flash nozzle. A flash nozzle utilizes a pressure drop that induces cavitation in the spray solution prior to exiting the nozzle orifice to induce droplet formation. A sweep gas around the orifice is used to eliminate or reduce solids build-up during operation.

In another aspect, the matrix material comprises a polymer. In still another aspect, the particles comprise a solid amorphous dispersion of the active agent and a polymer.

In another embodiment, a process of spray drying includes delivering a spray solution to a spray-drying apparatus. The spray drying apparatus comprises a drying chamber with a first end, a second end, and at least one side wall extending between the first and second ends to define an interior of the drying chamber and having a center axis. The spray solution is initially at a temperature T₁ and the delivering of the spray solution to the spray-drying apparatus further comprises directing the spray solution to a heat exchanger to increase the temperature of the spray solution to a temperature T₂, wherein temperature T₂ is greater than temperature T₁. The method includes forming a plurality of droplets by atomizing a spray solution using a nozzle positioned at the first end of the drying chamber and delivering the plurality of droplets into the drying chamber. The drying chamber comprises a second end and at least one side wall extending between the first and second ends to define an interior of the drying chamber and having a center axis. At least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from the center axis at a first angle relative to the center axis. The first angle is at least 5 degrees but less than 45 degrees. A ratio of the length between the first and second ends of the drying chamber to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1. A drying gas is delivered into the drying chamber to at least partially dry the plurality of droplets to form a plurality of particles and the plurality of particles are directed out of the drying chamber.

In another embodiment, a process of spray drying includes forming a plurality of droplets by atomizing a spray solution using a nozzle positioned at the first end of the drying chamber and delivering the plurality of droplets into the drying chamber. The drying chamber comprises a second end and at least one side wall extending between the first and second ends to define an interior of the drying chamber and having a center axis. At least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from the center axis at a first angle relative to the center axis. The first angle being at least 5 degrees but less than 45 degrees and a ratio of the length between the first and second ends of the drying chamber to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1. Drying gas is delivered into the drying chamber in substantially parallel flow to at least partially dry the plurality of droplets to form a plurality of particles. The plurality of particles are directed out of the drying chamber. The spray solution is initially at a temperature T₁ and is directed to a heat exchanger to increase the temperature of the spray solution to temperature T₂ prior to atomization of the spray solution, wherein temperature T₂ is greater than temperature T₁.

In some embodiments, a velocity vector of the drying gas entering the drying chamber averaged over the opposing internal surfaces of the interior of the drying chamber is essentially parallel to the center axis of the drying chamber and is substantially toward the second end of the drying chamber. In other embodiments, any circulation cells near the first end of the drying chamber in the vicinity of the nozzle have diameters of less than 20% of the maximum width between opposing internal surfaces of the interior of the drying chamber in the vicinity of the circulation cells.

In other embodiments, a velocity vector of the drying gas entering the drying chamber averaged over the opposing internal surfaces of the interior of the drying chamber is essentially parallel to the center axis of the drying chamber and is substantially toward the second end of the drying chamber. Any circulation cells near the first end of the drying chamber in the vicinity of the nozzle have diameters of less than 20% of the maximum width between opposing internal surfaces of the interior of the drying chamber.

In some embodiments, the spray solution is a suspension comprising a solute and a solvent. In some embodiments, the spray solution can be at a pressure that is greater than the vapor pressure of the solvent at temperature T₂. In other embodiments, the spray solution is delivered to the nozzle at a temperature T₃, and temperature T₃ is less than or equal to temperature T₂. In other embodiments, the drying gas forms drying gas streamlines at the first end of the drying chamber that are toward the second end of the drying chamber, and the streamlines have vectors that are between the vector formed by the center axis of the drying chamber and the vector defined by the walls of the drying chamber.

In other embodiments, the droplets are delivered into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 45 degrees. In some embodiments, the first angle is at least 5 degrees but less than 30 degrees relative to the center axis. In some embodiments, the nozzle can be configured to atomize a liquid into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 30 degrees. In some embodiments, the first angle is at least 5 degrees but less than 20 degrees relative to the center axis. In some embodiments, droplets are delivered into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 20 degrees.

In some embodiments, the nozzle is a flash nozzle, with the flash nozzle comprising a central tube and an outer tube. The spray solution is delivered through the central tube and a sweep gas being delivered through the outer tube. In some embodiments, the central tube has a first outer diameter and a first inner diameter at an inlet, and a second outer diameter and a second inner diameter at an outlet. The first outer diameter is greater than the second outer diameter. The first inner diameter and the second inner diameter are substantially the same. In some embodiments, the central tube has an inner diameter and an outer diameter, forming a wall thickness of the central tube. In one embodiment, the wall thickness of the central tube at the inlet is greater than the wall thickness of the central tube at the outlet.

In some embodiments, the spray solution comprises an active agent and an excipient. In one embodiment, a spray solution comprises colloidal materials, dissolve materials, and mixtures thereof. In some embodiments, the spray solution does not comprise a suspension, meaning that the spray solution does not contain crystalline or solid materials having diameters greater than 1000 nm. In this embodiment, the spray solution comprises dissolved materials, colloidal materials, and mixtures thereof. In another embodiment, the spray solution comprises dissolved materials.

In another embodiment, a method of spray drying includes forming a feed suspension comprising an active agent, a matrix material and a solvent. A spray solution can be formed by directing the feed suspension to a heat exchanger, thereby increasing the temperature of the feed suspension from a first temperature T₁ to a second temperature T₂ that is greater than temperature T₁. The spray solution can be at a pressure that is greater than the vapor pressure of the solvent at temperature T₂. The spray solution can be delivered to a nozzle positioned at a first end of a drying chamber, with the drying chamber further comprising a second end and at least one side wall extending between the first and second ends to define an interior of the drying chamber and having a center axis. At least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber can extend away from the center axis at a first angle relative to the center axis that is between 5 degrees and 45 degrees. A plurality of droplets can be formed by atomizing the spray solution using the nozzle and delivering the plurality of droplets into the drying chamber at an angle that is equal to or less than the first angle. A drying gas can be delivered into the drying chamber to at least partially dry the plurality of droplets to form a plurality of particles and the plurality of particles can be directed out of the drying chamber. In some embodiments, a ratio of the length between the first and second ends of the drying chamber to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1.

In some embodiments, the solvent comprises an organic solvent.

In another embodiment, a process for producing a composition comprises forming a feed suspension comprising an active agent, a matrix material and a solvent, wherein the feed suspension is at a temperature T₁. A spray solution can be formed by directing the feed suspension to a heat exchanger, thereby increasing the temperature of the feed suspension to a temperature T₂, wherein temperature T₂ is greater than temperature T₁, the spray solution is at a pressure that is greater than the vapor pressure of the solvent at temperature T₂, and the active agent and the matrix material are soluble in the solvent at temperature T₂. The spray solution can be directed to a spray-drying apparatus that comprises a drying chamber, a nozzle, and a source of heated drying gas. The drying chamber can have a first end, a second, and at least one side wall extending between the first and second ends to define an interior of the drying chamber. The drying chamber can have a ratio of the length between the first and second ends of the drying chamber to a maximum width between opposing internal surfaces of the interior of the drying chamber that is at least 5 to 1. The nozzle can be configured to atomize the spray solution into droplets. The spray solution can be atomized into droplets in the drying chamber by the nozzle, with the spray solution being delivered to the nozzle at a temperature T₃. The droplets can be contacted with the heated drying gas to remove at least a portion of the solvent from the droplets to form a plurality of particles comprising the active agent and the matrix material, and the particles can be collected.

In another embodiment, a spray-drying apparatus comprises a feed suspension tank for storing a feed suspension and a heating device configured to heat the feed suspension to form a spray solution. The apparatus can also include a drying-gas conduit, a drying chamber, and a nozzle positioned at the first end of the drying chamber. The can be configured to atomize the spray solution and spray the atomized spray solution into the interior of the drying chamber. The drying chamber can have a first end, a second end, and at least one side wall extending between the first and second ends to define an interior of the drying chamber having a center axis. The drying-gas conduit can be in fluid communication with the drying chamber and configured to direct a flow of drying gas into the drying chamber. At least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from the center axis at a first angle relative to the center axis, with the first angle being at least 5 degrees but less than 45 degrees.

In some embodiments, a ratio of the length between the first and second ends of the drying chamber to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1. In some embodiments, the heating device is a heat exchanger coupled between with the feed suspension tank and the nozzle. The heat exchanger can include a feed suspension inlet and a spray solution outlet.

The disclosed processes provide one or more advantages over a conventional spray-drying process. Certain embodiments of the disclosed processes can increase the throughput of a spray dryer by forming a spray solution that has a higher concentration at a higher temperature than conventional processes. For example, a higher degree of homogeneity and more uniform particle size can be provided, which improves the throughput of spray-drying equipment and provides a safe, reproducible process to produce high-quality product.

Certain embodiments of the disclosed processes can increase the throughput of a spray dryer by forming a spray solution that has a higher concentration at a higher temperature than conventional processes. Operating in this regime generally leads to spray-dried products that are more homogeneous and more uniform. In addition, the disclosed processes result in rapid evaporation of the solvent and shorter times to solidification than conventional processes. Furthermore, in some embodiments, the process results in improved atomization of the spray solution relative to conventional processes due to the temperature of the spray solution when it is atomized being above the boiling point of the solvent at the pressure of the drying chamber.

The foregoing and other objects, features, and advantages of the disclosed embodiments will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a spray-drying apparatus.

FIG. 2 is an enlarged cross-sectional view of one embodiment of a drying chamber.

FIG. 3 is a side view of an embodiment of the drying chamber of a spray-drying apparatus.

FIG. 4 shows velocity contours for one embodiment of the spray-drying apparatus.

FIG. 5 is an enlarged view of a portion of a drying chamber, shown with a nozzle delivering atomized spray solution into the drying chamber.

FIG. 6 is an enlarged view of another embodiment of a drying chamber, shown with a nozzle delivering atomized spray solution into the drying chamber.

FIG. 7 illustrates another embodiment of a drying chamber.

FIG. 8 is a graph illustrating particle residence time in a drying chamber of a spray-drying apparatus as described herein.

FIG. 9 is a schematic of a spray-drying apparatus suitable for use in performing a process of a disclosed embodiment.

FIG. 10 is a schematic of a flash nozzle, suitable for use with embodiments of spray-drying apparatuses disclosed herein.

FIG. 11 is a figure showing the results of powder X-ray diffraction of the samples of Example 10, Control 1, and Control 2.

FIG. 12 is a schematic view of a spray-drying apparatus.

DETAILED DESCRIPTION

Various embodiments of spray-drying apparatuses and their methods of use are disclosed herein. The following description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Various changes to the described embodiment may be made in the function and arrangement of the elements described herein without departing from the scope of the invention.

As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” generally means electrically, electromagnetically, and/or physically (e.g., mechanically or chemically) coupled or linked and does not exclude the presence of intermediate elements between the coupled or associated items absent specific contrary language.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, percentages, measurements, distances, ratios, and so forth, as used in the specification or claims are to be understood as being modified by the term “about.” Accordingly, unless otherwise indicated, implicitly or explicitly, the numerical parameters set forth are approximations that may depend on the desired properties sought and/or limits of detection under standard test conditions/methods. When directly and explicitly distinguishing embodiments from discussed prior art, the embodiment numbers are not approximates unless the word “about” is recited.

Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed.

As used herein, the terms matrix material and excipient may be used interchangeably. Matrix materials and excipients may be considered solutes. In some embodiments, the term solutes includes active agents. In other embodiments, the term solutes includes at least one active agent and at least one matrix material. In other embodiments, the term solutes includes at least one active agent and at least one excipient.

Conventional spray-drying apparatuses require a drying chamber of a relatively large diameter to provide the desired throughput of fluid feed stock. These large diameter drying chambers can be relatively expensive to manufacture and operate due to increased air handling, utility, and construction costs. Also, the combination of the large drying chamber and the manner in which drying gas enters the chamber results in non-parallel gas flow with large circulation cells. Such gas flow patterns can carry particles to the chamber wall before complete drying, can lead to long residence times, and can even result in particles contacting hot gas and hot metal surfaces near the drying gas entrance.

In addition, particle residence times in these large drying chambers can be quite long and variable, causing at least some particles to be exposed to elevated temperatures and elevated solvent concentrations, which can damage or reduce the efficacies of active agents in the particles. The particle residence time distributions in large drying chambers can also be quite broad, leading to large differences in particle properties within a single batch of spray dried powder. An apparatus with a smaller diameter and with substantially parallel flow in the vicinity of the spray nozzle results in shorter particle residence times, and a much narrower particle residence time distribution, resulting in more uniform particle properties.

The collection efficiencies of conventional larger diameter drying chambers can also be relatively poor, due to the lower pressures maintained in these larger diameter drying chambers, especially when spray drying particles with relatively small diameters, such as those with diameters of 10 μm or less. In addition, the larger diameter of conventional spray-drying apparatuses leads to a high surface area and high surface area to volume ratios, and a corresponding high heat loss. An apparatus with a smaller diameter and correspondingly smaller surface area and/or surface to volume ratio, can reduce heat loss, making the spray drying process more efficient. The larger diameter of conventional spray-drying apparatuses leads to large drying-chamber volumes, making operation at elevated pressures expensive due to the increased strength required to maintain a large volume under elevated pressure. By using a relatively small volume drying chamber, higher pressures can be achieved within the drying chamber, resulting in lower capital costs, and higher particle collection efficiencies. Conventional spray drying apparatuses also require a large room to accommodate all the equipment. By using a small volume drying chamber, the room space required is greatly reduced, further reducing capital costs required for installation and operation of the spray dryer. The larger diameters and higher surface areas of conventional spray-drying apparatuses also leads to large amounts of cleaning agents required after each use and when changing from one product to another. Thus, a smaller diameter dryer with a smaller surface area can reduce the amount of cleaning agents required by the spray-drying system.

Accordingly, there is a need for an improved spray-drying apparatus design that results in the production of spray-dried solids with lower equipment costs, exposure of particles to lower maximum temperatures, shorter duration of exposure to elevated temperatures, more uniform drying conditions for all droplets and particles, and improved collection efficiency.

In particular, the combination of (1) a smaller volume, larger aspect ratio drying chamber, (2) atomization of the liquid to be dried such that the droplets are directed parallel to or away from the drying chamber walls, (3) introduction of the drying gas such that it enters the drying chamber in a uniform flow pattern that is substantially parallel to the center axis of the drying chamber, and/or (4) construction of the drying gas conduit and drying chamber such that there are few gas circulation cells, results in extremely efficient drying, uniform and relatively short exposure of droplets and particles to heat and solvent vapors, and high product recovery.

An embodiment of the disclosed spray-drying apparatus is shown in FIG. 1. Although the following embodiments illustrate spray-drying apparatuses that are generally circular in cross section, it should be understood that unless contrary to the disclosed processes herein, the apparatus can take any other cross-sectional shapes suitable for spray drying a spray solution, including, for example, square, rectangular, and octagonal shapes, among others.

As shown in FIG. 1, spray-drying apparatus 10 can comprise a drying chamber 40, a nozzle 50, and a particle collection member 60. In one embodiment, the spray-drying apparatus 10 can be utilized as follows. A spray solution 26 can be formed by mixing a solute with a solvent. In one embodiment, the spray solution may be stored in a feed tank (not shown in FIG. 1). The spray solution may be kept homogenous using a mixing means (also not shown in FIG. 1). In another embodiment, the spray solution may be prepared continuously.

As used herein, the term “spray solution” means a composition including a solute and a solvent. The term “solute” means a material that is desired to be spray dried. In one embodiment, the solute comprises at least one active agent. In another embodiment, the solute comprises at least one excipient. In still another embodiment, the solute comprises a mixture of at least one active agent and at least one excipient.

In one embodiment, the spray solution 26 comprises an active agent and a solvent. In another embodiment, the spray solution 26 comprises an excipient and a solvent. In still another embodiment, the spray solution 26 comprises an active agent, at least one excipient, and a solvent. The spray solution 26 can include, for example, mixtures, solutions, and/or suspensions. For example, in one embodiment, the active agent can be dissolved in the solvent. In another embodiment, a portion of the active agent can be suspended or not dissolved in the solvent. In another embodiment, the active agent can be dissolved in the solvent, while a portion of an excipient is dissolved in the solvent. In another embodiment, a portion of the active agent, a portion of an excipient, or a portion of both an active agent and an excipient can be suspended or not dissolved in the solvent.

In one embodiment, the spray solution 26 consists essentially of an active agent, at least one excipient, and a solvent. In still another embodiment, the spray solution consists of an active agent, at least one excipient, and a solvent. In yet another embodiment, the spray solution consists of particles of active agent suspended in a solution of at least one excipient dissolved in the solvent. In yet another embodiment, the spray solution also contains particles of one or more excipients suspended in the solution. It will be recognized that in such spray solutions, a portion of the active agent and the one or more excipients may dissolve up to their solubility limits at the temperature of the spray solution.

As used herein, “active agent” means a drug, medicament, pharmaceutical, therapeutic agent, nutraceutical, nutrient, or other compound. The active agent may be a “small molecule,” generally having a molecular weight of 2000 Daltons or less. The active agent may also be a “biological active.” Biological actives include proteins, antibodies, antibody fragments, peptides, oligoneucleotides, vaccines, and various derivatives of such materials. In one embodiment, the active agent is a small molecule. In another embodiment, the active agent is a biological active. In still another embodiment, the active agent is a mixture of a small molecule and a biological active. In yet another embodiment, the compositions made by certain of the disclosed processes comprise two or more active agents.

As used herein, the term “feed suspension” means a composition comprising an active agent, a matrix material, and a solvent, wherein at least a portion of the active agent, a portion of the matrix material, or a portion of both active agent and matrix material are suspended or not dissolved in the solvent. In some embodiments, the solvent is an organic solvent. In one embodiment, the feed suspension consists essentially of an active agent, a matrix material, and a solvent. In still another embodiment, the feed suspension consists of an active agent, a matrix material, and a solvent. In yet another embodiment, the feed suspension consists of particles of active agent suspended in a solution of matrix material dissolved in the solvent. It will be recognized that in such feed suspensions, a portion of the active agent and the matrix material may dissolve up to their solubility limits at the temperature of the feed suspension.

As used herein, the term “solvent” means water or other compounds, such as an organic compound, that can be used to dissolve or suspend the solute. In one embodiment, the solvent is volatile, having an ambient-pressure boiling point of 150° C. or less. In another embodiment, the solvent has an ambient-pressure boiling point of 100° C. or less. Suitable solvents can include water; alcohols such as methanol, ethanol, n-propanol, isopropanol, and butanol; ketones such as acetone, methyl ethyl ketone and methyl isobutyl ketone; esters such as ethyl acetate and propyl acetate; and various other solvents, such as tetrahydrofuran, acetonitrile, methylene chloride, toluene, and 1,1,1-trichloroethane. Lower volatility solvents such as dimethylacetamide or dimethylsulfoxide can also be used, generally in combination with a volatile solvent. Mixtures of solvents, such as 50% methanol and 50% acetone, can also be used, as can mixtures with water.

As used herein, the term “organic solvent” means a solvent that is an organic compound. In one embodiment, the solvent is volatile, having an ambient-pressure boiling point of 150° C. or less. In another embodiment, the solvent has an ambient-pressure boiling point of 100° C. or less. Suitable solvents include alcohols such as methanol, ethanol, n-propanol, isopropanol, and butanol; ketones such as acetone, methyl ethyl ketone and methyl isobutyl ketone; esters such as ethyl acetate and propyl acetate; and various other solvents, such as tetrahydrofuran, acetonitrile, methylene chloride, toluene, and 1,1,1-trichloroethane. Lower volatility solvents such as dimethylacetamide or dimethylsulfoxide can also be used, generally in combination with a volatile solvent. Mixtures of solvents, such as 50% methanol and 50% acetone, can also be used, as can mixtures with water. In one embodiment, the organic solvent contains less than 50 wt % water. In another embodiment, the organic solvent contains less than 25 wt % water. In still another embodiment, the organic solvent contains less than 10 wt % water. In yet another embodiment, the organic solvent contains less than 5 wt % water. In another embodiment, the organic solvent contains essentially no water.

As used herein, the term “excipient” means a substance that may be beneficial to include in a composition with an active agent. The term “excipient” includes inert substances as well as functional excipients that may result in beneficial properties of the composition. Exemplary excipients include but are not limited to polymers, sugars, salts, buffers, fats, fillers, disintegrating agents, binders, surfactants, high surface area substrates, flavorants, carriers, matrix materials, and so forth.

The spray solution can be delivered to a nozzle 50 via a pump or other delivery device (not shown). Nozzle 50 atomizes the spray solution into the drying chamber in the form of droplets 44. Drying gas 42 flows through a drying-gas conduit 41, which is in fluid communication with the first end 70 of drying chamber 40. In one embodiment, the first end 70 of the drying chamber is located at the position where the spray solution exits the nozzle 50. In one embodiment, the drying-gas conduit 41 is configured to allow the drying gas 42 to enter the drying chamber 40 with substantially parallel flow. As used herein, “substantially parallel flow” means that the flow of drying gas 42 entering the drying chamber satisfies at least one of the following two conditions. First, the velocity vector of the drying gas 42 averaged over the cross-section of the first end 70 of the drying chamber 40 is essentially parallel to the center axis of drying chamber 40 and is substantially towards the second end 72 of drying chamber 40. Second, any circulation cells near the first end 70 of the drying chamber 40 in the vicinity of nozzle 50 are small, with the diameter of the circulation cells being less than 20% of the maximum width between opposing internal surfaces of the interior of the drying chamber 40 in the area of the circulation cell. As used herein, “essentially parallel” means that the velocity vector averaged over the cross-section of the first end 70 of the drying chamber 40 has a direction that ranges between the center axis of the drying chamber and the angle formed by the walls 48 and the center axis at the first end 70. In one embodiment, the drying gas entering the drying chamber meets both of these conditions.

In another embodiment, the drying gas streamlines, defined as the local gas velocity vectors, are essentially all directed from the first end 70 of the drying chamber 40 toward the second end 72 of the drying chamber 40. In addition, these drying gas streamlines have vectors that are between the vector defined by the center axis of the drying chamber 40 and the vectors defined by the walls 48 of the drying chamber.

To achieve substantially parallel flow, the drying-gas conduit 41 and first end 70 should generally be free from sharp surfaces or protrusions that could significantly disrupt the flow of the drying gas 42. In addition, the walls of the drying gas conduit 41 and the drying chamber 40 should be generally parallel to each other where the drying gas conduit 41 is coupled to the drying chamber 40, particularly when it is coupled in the vicinity of the nozzle. As used in this context herein, “generally parallel” means that an angle formed between the walls of the gas conduit and drying chamber relative to the center axis of the drying chamber 40 is less than 45 degrees. In one embodiment, the drying-gas conduit 41 contains at least one flow straightener, such as a mesh, screen, or perforated plate that results in substantially parallel flow when the drying gas 42 enters the drying chamber 40. In another embodiment, the drying gas conduit 41 is smooth, having a radius of curvature that is at least twice the width between opposing side walls at the first end 70 of the drying chamber 40.

The drying gas 42 is combined with the droplets 44 in the drying chamber 40. In the drying chamber 40, at least a portion of the solvent is removed from the droplets 44 to form an exiting fluid 46 comprising evaporated solvent and drying gas 62 and a plurality of at least partially dried particles 66. The term “exiting fluid” refers to any fluids, particles, or combinations of fluids and particles that exit the drying chamber 40.

The exiting fluid 46 exits the drying chamber at the second end 72 through exit conduit 49, and can be directed to a particle collection member 60. Suitable particle collection members include cyclones, filters, electrostatic particle collectors, and the like. In the particle collection member 60, the evaporated solvent and drying gas 62 can be separated from the plurality of particles 66, allowing for collection of the particles 66.

As shown in FIGS. 1 and 3, drying chamber 40 has a first end 70 and a second end 72. First end 70 can be an inlet for receiving the nozzle and can be coupled to the drying gas conduit 41 for receiving the drying gas 42. Second end 72 can be an outlet that can be coupled to an exit conduit 49, and then to a particle collection member 60 or other such device to receive and collect the particles as they exit drying chamber 40. The interior volume of drying chamber 40 can be defined by one or more side walls 48 that extend between first and second ends 70, 72. If drying chamber 40 comprises a single integral structure, a single side wall 48 can extend from first end 70 to second end 72. Alternatively, drying chamber 40 can be formed of sections that include multiple side walls 48 that are coupled together to form a single drying chamber.

In one embodiment, the first end 70 of the drying chamber 40 is located where the spray solution exits the nozzle 50 via one or more outlets in the nozzle 50, while the second end 72 is located where the exit conduit 49 starts.

FIG. 2 shows an enlarged cross-sectional view of an embodiment of the first end 70 of drying chamber 40. Nozzle 50 can be centrally positioned at first end 70 of drying chamber 40 along the center axis E-E′ of the drying chamber, which generally extends longitudinally along the center axis of drying chamber 40. Nozzle 50 can have a spray pattern such that droplets 44 are directed out of nozzle 50 at a maximum spray angle A1. Angle A1 can be equal to an angle A2 formed between center axis E-E′ and a side wall 48 of drying chamber 40 that is adjacent to or in the vicinity of nozzle 50. In one embodiment, angles A1 and A2 are generally equal, that is, within about 5 degrees of one another. Drying gas 42 enters the drying chamber 40 via drying gas conduit 41 with an exit center axis E-E″. In one embodiment, drying gas conduit 41 exit center axis E-E″ is parallel to the center axis of the drying chamber E-E′. In another embodiment, E-E″ and E-E′ are approximately coincident.

Generally, the temperature and flow rate of the drying gas should be chosen so that the droplets of spray solution are dry enough by the time they reach the wall of the apparatus that, at least on the particle surface, they are essentially solid, form a fine powder, and do not stick to the apparatus wall. The actual length of time to achieve this level of dryness depends on the size of the droplets and the conditions at which the process is operated. In conventional systems, droplets exit the nozzle and are directed on a range of trajectories such that many of their trajectories are towards the side walls. In addition to increasing residence time, directing droplets towards the side walls requires that the distance from the nozzle to the side wall be sufficiently large so that the ejected droplets have enough time to dry, at least on the surface of the droplets, before contacting the side wall. By providing a nozzle and angled side wall as shown in FIG. 1, however, the width (e.g., diameter) of the spray-drying apparatus can be reduced since the droplets are directed generally parallel to the side wall. Accordingly, by forming angles A1 and A2 generally equal to one another, droplets can be provided with sufficient time to dry, without requiring a wide drying chamber.

One of ordinary skill will understand that the required length of the angled side wall will be a function of (1) the droplet diameter, (2) the droplet velocity, (3) the drying gas velocity, and (4) the time for the droplet to become sufficiently dry on the surface so that the particle doesn't stick to the walls of the drying chamber. Generally, larger droplet diameters will require longer lengths of the angled side wall to ensure the droplet is sufficiently dry before contacting the interior walls of the drying chamber.

To the extent that one of angles A1 and A2 are different, angle A1 is somewhat smaller than angle A2 to reduce the chance that atomized spray solution or particles will contact the side wall of the drying chamber.

Accordingly, if the maximum spray angle A1 does not exceed the angle A2 formed by side wall 48, droplets or particles exiting nozzle 50 are directed away from or parallel to the side wall and not towards side wall 48. To substantially direct the droplets in a direction generally parallel to the side wall of the drying chamber, angle A1 is 45 degrees or less. Angle A1 can also be 40 degrees or less, 35 degrees or less, 30 degrees or less, 25 degrees or less, 20 degrees or less, 15 degrees or less, 10 degrees or less, or 5 degrees or less.

As shown in FIGS. 1 and 2, droplets ejected from nozzle 50 with a maximum spray pattern of 45 degrees or less can be directed along a path that generally does not intersect with side wall 48 that is adjacent to or in the vicinity of nozzle 50. In the illustrated embodiment of FIG. 2, angle A1 is 15 degrees.

As described above, in one embodiment, angle A2 is substantially equal to angle A1. Thus, if angle A2 is equal to 30 degrees and nozzle 50 has a maximum spray angle A1 that is equal to or less than 30 degrees, droplets 44 are directed away from or along (i.e., parallel to) the inner surface of side wall 48 and generally prevented from contacting the side wall of the drying chamber. In the illustrated embodiment of FIG. 2, angle A1 is 15 degrees and angle A2 is substantially equal to A1 (i.e., angle A2 is about 15 degrees).

FIG. 3 shows a cross-section of an embodiment of drying chamber 40. Position A is the inlet (first end 70) and Position D is the outlet (second end 72) of drying chamber 40. As shown in other embodiments, a nozzle can be located at or near position A. In this embodiment, the drying chamber includes three main sections. Section A-B is an expanding tapered section, Section B-C is a straight section, and Section C-D is a contracting tapered section. In one embodiment, the expanding tapered section A-B can be 75-100 cm long and can be narrowest at the inlet end (Position A) and widest at a position furthest from the inlet end. The straight section B-C can be 25-50 cm long and can have a substantially constant width along its length. The contracting tapered section C-D can be 25-50 cm long and can be narrowest at the outlet end (second end 72, Position D) and widest at a position furthest from the second end 72. Accordingly, in one embodiment, a total length of the drying chamber (i.e., the length of section A-B+the length of section B-C+the length of section C-D) can vary from 125 cm to 200 cm. One of ordinary skill will understand that drying chambers with other lengths and widths can be constructed and be within the scope of the invention, and the invention is not limited to the lengths and widths described above.

The three sections can be separate side walls 48 that are coupled or connected together in any conventional manner (e.g., mechanically and/or chemically). Alternatively, the three sections can be integrally formed of a single side wall member.

In the embodiment shown in FIG. 3, the width of the apparatus is 25.4 cm (10 inches). The width at any point along the length of the drying chamber is the distance between opposing internal surfaces of the side wall(s). Thus, the ratio of the length to the maximum width of the drying chamber is at least 5 to 1 (e.g., the length is at least 125 cm if the width is 25 cm) and can even be greater than 6 to 1. In one embodiment, the ratio of the length to the maximum width of the drying chamber can be even greater, such as 10 to 1, or more. By providing a drying chamber that has a length that is significantly greater than its width, residence time in the drying chamber can be greatly reduced. Instead of being captured and recirculated within the drying chamber, droplets or particles ejected from the nozzle are directed towards the second end 72 and out of the drying chamber 40 through exit conduit 49. The substantial length (relative to the width) provides enough time for the droplets or particles to be sufficiently dried before exiting the drying chamber.

In one embodiment, section A-B can be 86.4 cm (34 inches) long and tappers from 7.6 cm (3 inches) wide at Position A to 25.4 cm (10 inches) wide at Position B. The straight section B-C can be 40.6 cm (16 inches) long. The contracting tapered section C-D can be 40.6 cm (16 inches) long and tappers from 25.4 cm (10 inches) wide at Position C to 10.2 cm (4 inches) wide at Position D. Thus, in this specific implementation, the ratio of the length to the maximum width of the drying chamber is 6.6 to 1 (i.e., 167.6 cm to 25.4 cm).

In addition, in the above embodiment, although the second end 72 has an opening with a smaller diameter (10 cm) than the diameter of the maximum width between opposing surfaces of the interior of the drying chamber (25 cm), the ratio of the maximum width between opposing surfaces of the interior of the drying chamber to the diameter at the second end of the drying chamber interior is less than 6 to 1. In other embodiments, the ratio of the maximum width between opposing surfaces of the interior of the drying chamber to the diameter at the second end of the drying chamber interior may be less than 5 to 1, less than 4 to 1, less than 3 to 1, or even less than 2.5 to 1. Generally, to aid in the collection of particles, the ratio of the maximum width between opposing surfaces of the interior of the drying chamber to the diameter at the second end of the drying chamber interior should be greater than 1.1 to 1.

In one embodiment of FIG. 3, the apparatus has a generally cylindrical shape. The first end of the drying chamber (70) is located at Position A. The second end of the drying chamber (72) is located at Position D. The cylindrical walls of the drying chamber (48) define an interior of the drying chamber having a center axis. The nozzle is located at or near the first end (70) of the drying chamber at Position A. A portion of the cylindrical walls of the drying chamber (48) extends away from the center axis at a first angel relative to the center axis (Section A-B). The drying chamber further comprises a cylindrical portion of generally constant width at Section B-C. The drying chamber further comprises a second tapered portion (Section C-D) at the second end (72) that is narrowest at the second end (72, Position D), and widest at Position C. The ratio of the length between the first end (70) and the second end (72) (that is, the length between Positions A and D) to the maximum width between opposing internal surfaces of the interior of the drying chamber (that is, at Position B) is at least 5 to 1. In one embodiment, a ratio of the maximum width (at Position B) to the width at the second end (72) of the drying chamber (at Position D) is less than 3 to 1.

In one embodiment, the plurality of particles produced in the apparatuses disclosed herein are inhalable particles that can be inhaled by a subject (e.g., human or animal). As used herein, the term “inhalation” refers to delivery to a subject through the mouth or nose. In one embodiment, the spray-dried particles are delivered to the “upper airways.” The term “upper airways” refers to delivery to nasal, oral, pharyngeal, and laryngeal passages, including the nose, mouth, nasopharynx, oropharynx, and larynx. In another embodiment, the spray-dried particles are delivered to the “lower airways.” The term “lower airways” refers to delivery to the trachea, bronchi, bronchioles, alveolar ducts, alveolar sacs, and alveoli.

In one embodiment, the particles have a mass median aerodynamic diameter (MMAD) of about 5 to 100 μm. In another embodiment, the particles have a MMAD of about 10 to 70 μm. Mass median aerodynamic diameter (MMAD) is the median aerodynamic diameter based on particle mass. In a sample of particles, 50% of the particles by weight will have an aerodynamic diameter greater than the MMAD, and 50% of the particles by weight will have an aerodynamic diameter smaller than the MMAD. In yet another embodiment, the particles have an average diameter of 50 μm, or even 40 μm, or 30 μm. In other embodiments, the particles can have an MMAD of less than about 20 μm, or even less than about 10 μm. In another embodiment, the particles have a MMAD ranging from 0.5 μm to 10 μm. In still another embodiment, the particles have a MMAD ranging from 1 μm to 5 μm.

In one embodiment, the particles are intended for inhalation and have a MMAD of 0.5 to 100 μm. In another embodiment, the particles are intended for inhalation and have a MMAD of 0.5 to 70 μm.

In one embodiment, the particles are intended for delivery to the upper airways, and have a MMAD of greater than 10 μm. In another embodiment, the particles are intended for delivery to the upper airways and have a MMAD of 10 to 100 μm, and wherein the weight fraction of particles having an aerodynamic diameter of less than 10 μm is less than 0.1. In another embodiment, the particles are intended for delivery to the upper airways and have a MMAD of 10 to 70 μm, and the weight fraction of particles having an aerodynamic diameter of less than 10 μm is less than 0.1.

In another embodiment, the particles are intended for delivery to the lower airways, and have a MMAD of less than 10 μm. In one embodiment, the particles are intended for delivery to the lower airways, and have a MMAD of 0.5 to 10 μm, and the weight fraction of particles having an aerodynamic diameter of greater than 10 μm is less than 0.1. In another embodiment, the particles are intended for delivery to the lower airways, and have a MMAD of 0.5 to 7 μm, and the weight fraction of particles having an aerodynamic diameter of greater than 7 μm is less than 0.1.

In some embodiments of inhalable particles, the active agent comprises a drug, medicament, pharmaceutical, therapeutic agent, nutraceutical, nutrient, or other compound suitable for treating, diagnosing, preventing, or otherwise affecting a particular physical condition or state of the patient.

Inhalable particles formed using the spray-drying apparatuses described herein can be dispersed in an inhalation device, such as an inhaler, without producing significant amounts of one or more of the following undesirable side effects when administered via inhalation to a subject: cough, emesis, toxic build-up in the lung, inflammation, reduced lung function. One measure of lung function is the FEV₁ (forced expiratory volume in one second) test, which measures the volume exhaled during the first second of a forced expiratory maneuver started from the level of total lung capacity.

In one embodiment, the concentration of solvent remaining in the particles when they are collected (that is, the concentration of residual solvent) is less than 10 wt % based on the total weight of the particles (i.e., the combined weight of the particle and solvent). In another embodiment, the concentration of residual solvent in the particles when they are collected is less than 5 wt %. In yet another embodiment, the concentration of residual solvent in the particles is less than 3 wt %. In another embodiment, a drying process subsequent to the spray-drying process may be used to remove residual solvent from the particles. Exemplary processes include tray drying, fluid-bed drying, vacuum drying, and other similar drying processes.

The drying gas may be virtually any gas, but to minimize the risk of fire or explosions due to ignition of flammable vapors, and to minimize undesirable oxidation of the active agent or other excipients, an inert gas such as nitrogen, nitrogen-enriched air, helium, or argon is utilized. The temperature of the drying gas at the gas inlet of apparatus 10 is typically from 20° to 300° C. The temperature of the product particles, drying gas, and evaporated solvent in the exiting fluid 46 typically ranges from 0° C. to 100° C.

By selecting a nozzle with a relatively small spray pattern angle (e.g., 30 degrees or less as measured relative to a central axis of the drying chamber) and providing a spray-drying chamber that generally encompasses only the space required to contain the spray plume contour of the nozzle, spray-dried solids can be produced satisfactorily with significantly smaller equipment. The smaller amount of space required for the spray-drying apparatuses disclosed herein relative to conventional spray-drying equipment, results in lower construction and utility costs (room size, air handling, etc.). In addition, the smaller size of the spray dryer allows it to be more easily enclosed in commercially available isolators, reducing operator exposure to highly potent compounds or aerosolized particles that can present an inhalation risk. This provides operators improved safety by further reducing potentially hazardous airborne particles.

The design also minimizes the amount of product buildup on the inside surfaces of the drying chamber, which improves production efficiency by reducing the amount of down time that is required for cleaning the drying chamber. By directing all particles generally parallel to the side walls—rather than directly towards the side walls as is the case in conventional spray-drying systems—few or none contact the side wall. Moreover, by directing a drying gas into the drying chamber in the manner shown in FIG. 6, even fewer particles contact the side walls since the drying gas further directs the droplets in a direction generally parallel to the side wall. Thus, by using the spray-drying apparatuses described herein, few, if any, droplets contact the side walls of the drying chamber, thereby reducing the amount of effort needed to clean the side walls.

In certain embodiments, the interior of the drying chamber has a volume that is 80 L or less, or even less than 70 L. In one embodiment, the drying chamber has a volume of between 55-65 L. By using a relatively small volume drying chamber, higher pressures can be achieved within the drying chamber. For example, a drying gas can be delivered into the drying chamber at 1200-1500 g/min, or even at 1300-1400 g/min. The temperature and type of gas can vary; however, temperatures of between 100 and 180 degrees Celsius are typical, with temperatures between 135 and 160 degrees Celsius being common. The small volume of the drying chamber in combination with the pressure of the drying gas results in high particle collection efficiencies at the second end of the drying chamber, as well as low residence times which can provide a number of benefits as described herein.

In one embodiment, the mean particle residence time of the spray-drying apparatuses disclosed herein can be less than 10 seconds. Shorter residence times can be obtained, and are sometimes desirable, such as less than 8 seconds, less than 5 seconds, or less than 3 seconds. In comparison, conventional spray-drying equipment often has residence times of 20 to 40 seconds for similar spray solution flow rates. The reduced particle residence time for the disclosed apparatuses reduces exposure to elevated drying gas temperatures that can cause degradation of active agents or excipients, allowing heat-sensitive materials to be spray dried. For example, compounds such as DNA, proteins, or antibodies that are not stable for long periods of time in a spray-drying chamber at high temperature and humidity, can be dried using the apparatuses disclosed herein due to the order of magnitude smaller residence time.

In addition to reducing the potential for degradation of active agents, shorter residence times also allow for the generation of a more consistent end product. Recirculation can cause widely varying residence times, which can result in large inconsistencies in particles as they exit the drying chamber. By reducing residence times and the related recirculation associated with longer residence times, spray-dried particles can be created with more consistent and predictable attributes, and with a narrower particle size distribution. Such consistency can be particularly important when spray-drying pharmaceutical compositions, such as the inhalable particles described herein. Thus, the spray-drying apparatuses disclosed herein can produce inhalable particles with a reduced variability in particle size and pharmacological activity. For example, Table 3 below illustrates the lower “Span” (a dimensionless parameter indicative of the uniformity of particle size distribution as described in more detail below) and improved fine particle fraction (FPF) of particles produced using a spray-drying apparatus as shown in FIG. 1 relative to conventional spray-drying systems.

FIG. 8 illustrates particle residence time in a drying chamber using a spray-drying apparatus as shown in FIG. 1. In particular, FIG. 8 shows the cumulative percentage of particles removed from the drying chamber over time. As shown in FIG. 8, when actively directing atomized spray solution into the drying chamber, 50% of all particles can be removed from the drying chamber within 2 seconds, 80% of all particles can be removed from the drying chamber within 3 seconds, 90% of all particles can be removed from the drying chamber within 4 seconds, and more than 95% of all particles can be removed from the drying chamber within 6 seconds, and 100% of all particles can be removed from the drying chamber within 8 seconds.

An additional advantage of the spray-drying apparatuses disclosed herein is found in the collection of small particles. For spray-drying particles having diameters of less than 10 μm using conventional spray-drying equipment, collection efficiency can be particularly poor. As discussed above, the smaller volume chambers of the spray-drying apparatuses disclosed herein can allow a higher operating pressure, resulting in more efficient particle collection in a cyclone.

FIG. 4 shows velocity contours for droplets and particles in one embodiment of the spray-drying chamber. The data in FIG. 4 illustrates that the droplets and particles move substantially parallel to the walls of the spray-drying chamber and contact with the walls by droplets or particles that have not been substantially dried is substantially prevented.

FIG. 5 illustrates an enlarged view of a nozzle 50 extending into a drying chamber 40. As described above, nozzle 50 can be generally aligned along a center axis of drying chamber 40. Drying gas 42 can be directed into drying chamber 40 and around nozzle 50. In one embodiment, one or more screens can be used to help maintain the central position of nozzle 50 within drying chamber 40. For example, as shown in FIG. 6, first and second mesh screen members 57, 59 can be positioned within the drying gas inlet member to secure nozzle 50 in the desired central position. Mesh screen members 57 and 59 may also be used to help produce substantially parallel flow of the drying gas when it enters the drying chamber 40.

FIG. 7 illustrates another embodiment of a spray-drying apparatus 100. Spray-drying apparatus 100 is generally similar to spray-drying apparatus 10. Instead of the three distinct regions (A-B, B-C, C-D) shown in FIG. 1, however, spray-drying apparatus 100 has a continuous curvature along the length of the side wall of the drying chamber 102. Like spray-drying apparatus 10, drying chamber 102 can increase in width from a first end 104 towards the center of drying chamber 102 and then decrease in width at a second end 106. Spray-drying apparatus 100, shown in FIG. 7, can have the same general dimensions (e.g., length, maximum and minimum widths, volume) as spray-drying apparatus 10. As described in more detail in the other embodiments, a nozzle can be coupled or secured at first end 104, and a collection member can be coupled or secured to second end 106 to capture at least partially dried particles as they exit the drying chamber 102.

As described above, the spray-drying apparatuses described herein are particularly suitable for producing particles of small average diameters, such as those suitable for inhalation (e.g., less than 10 μm). In other embodiments, however, the particles formed by the spray-drying apparatuses described herein can have an average diameter ranging from 0.5 μm to 500 μm. In another embodiment, the particles have a diameter ranging from 0.5 μm to 100 μm. In another embodiment, the particles have an average diameter of greater than 10 μm. In still another embodiment, the particles have an average diameter of greater than 20 μm. In still another embodiment, the particles have an average diameter of greater than 30 μm.

Spray-Dried Solid Compositions

In one embodiment, the spray-dried product formed by the spray-drying apparatus can comprise an active agent. In another embodiment, the spray-dried product formed by the spray-drying apparatus can comprise an excipient. In another embodiment, the spray-dried product formed by the spray-drying apparatus can comprise an active agent and at least one excipient. The excipient can be used to dilute the active and/or modify the properties of the composition. For instance, for inhalation applications, an excipient may improve or slow the rate of particle dissolution in lung fluid, lung fluid, bronchial mucus, or nasal mucus, reduce particle agglomeration, and/or improve reproducibility of the emitted dose. Examples of excipients include but are not limited to synthetic polymers, polysaccharides, derivatized polysaccharides, sugars, sugar alcohols, organic acids, salts of organic acids, inorganic salts, proteins, amino acids, phospholipids, and pharmaceutically acceptable salt forms, derivatives, and mixtures thereof. In another embodiment, the excipient is selected from polyvinyl pyrrolidone (PVP), polyethyleneoxide (PEO), poly(vinyl pyrrolidone-co-vinyl acetate), polymethacrylates, polyoxyethylene alkyl ethers, polyoxyethylene castor oils, polycaprolactam, polylactic acid, polyglycolic acid, poly(lactic-glycolic)acid, lipids, cellulose, pullulan, dextran, maltodextrin, hyaluronic acid, polysialic acid, chondroitin sulfate, heparin, fucoidan, pentosan polysulfate, spirulan, hydroxypropyl methyl cellulose (HPMC), hydroxypropyl cellulose (HPC), carboxymethyl ethylcellulose (CMEC), hydroxypropyl methylcellulose acetate succinate (HPMCAS), ethyl cellulose, cellulose acetate, cellulose butyrate, cellulose acetate butyrate, dextran polymer derivatives, trehalose, glucose, sucrose, raffinose, lactose, mannitol, erythritol, xylitol, polydextrose, oleic acid, citric acid, tartaric acid, edetic acid, malic acid, sodium citrate, sodium bicarbonate, albumin, gelatin, acacia, casein, caseinate, glycine, leucine, serine, alanine, isoleucine, tri-leucine, lecithin, phosphatidylcholine, and pharmaceutically acceptable forms, derivatives, and mixtures thereof. In one embodiment, the excipient is selected from lactose, mannitol, trehalose, sucrose, citric acid, leucine, glycine, dextran, oleic acid, and pharmaceutically acceptable salt forms, derivatives, and mixtures thereof. In still another embodiment, the excipient is selected from lactose, mannitol, trehalose, sucrose, citric acid, leucine, glycine, and pharmaceutically acceptable salt forms, derivatives, and mixtures thereof.

The apparatus can be used to form a wide variety of pharmaceutical compositions, including, but not limited to, spray dried amorphous drug, spray dried solid amorphous dispersions, amorphous drug absorbed to a high-surface area substrate, spray dried crystalline drug in a matrix, microparticles, nanoparticles, and spray-dried excipients.

EXAMPLES Actives Used in Examples

Active Agent 1 was 4-[2-(tert-butylamino)-1-hydroxyethyl]-2-(hydroxymethyl)phenol, also known as salbutamol sulfate, having the structure:

Active Agent 1 is freely soluble in water, and a Log P value of 0.11. The glass-transition temperature (T_(g)) of amorphous Active Agent 1 was determined by DSC to be 125° C.

Active Agent 2 was insulin, a heterotetrameric protein with a pKa of 5.39, Log P 0.22, and melting temperature (T_(m)) of 81° C.

Active Agent 3 was Peptide YY (PYY), a novel 36 amino-acid amidated hormone available from GenScript USA Inc. The peptide is soluble in water.

Example 1

(Active Agent 1: Dextran 10) A dry powder consisting of particles of a solid dispersion of Active Agent 1 was prepared by forming a spray solution containing 0.5 wt % Active Agent 1, 1.5 wt % Dextran 10 (Dextran having a molecular weight of 10,000 daltons, available from Amersham Sciences, Piscataway, N.J.), and 98.0 wt % water as follows: the active and solvent were combined in a 500 mL flask and mixed to form a clear solution, then the polymer was added to the solution and mixed for 30 minutes.

The spray solution was pressure fed using 30 psi nitrogen pressure feed from a 1 L pressure vessel to a 2-fluid nozzle (Spray Systems 1650 liquid, 120 air cap). Liquid feed was 25 mL/min, and atomizing nitrogen was 3.0 SCFM at 42 psi into an apparatus substantially similar to that shown in FIG. 1. The inlet nitrogen gas at a flow of 1340 g/min was heated to 155° C. and introduced to the spray dryer. The exit temperature of the drying gas was 55° C. The dried material was pneumatically conveyed through reducing-sized ductwork to a 3-inch outside diameter cyclone. The resulting solid dispersion particles were collected in a 20 mL jar attached to the bottom of the cyclone. The evaporated solvent and drying gas exited the dryer through the top of the cyclone, and were conditioned by a filter and scrubber. The 5.1 g collected of so-formed solid dispersion particles were then dried under vacuum desiccation at room temperature.

Dispersion particles were characterized using a Malvern Particle Size Analyzer, available from Malvern Instruments Ltd. of Framingham, Mass. The data obtained includes D₁₀, the diameter corresponding to the diameter of particles that make up 10% of the total volume containing particles of equal or smaller diameter, and D₉₀, the diameter corresponding to the diameter of particles that make up 90% of the total volume containing particles of equal or smaller diameter. Another parameter is “Span,” defined as

${{Span} = \frac{D_{90} - D_{10}}{D_{50}}},$

(where D₅₀ is the diameter corresponding to the diameter of particles that make up 50% of the total volume containing particles of equal of smaller diameter). Span, sometimes referred to in the art as the Relative Span Factor or RSF, is a dimensionless parameter indicative of the uniformity of the particle size distribution. Generally, the lower the Span, the more narrow the particle size distribution, resulting in improved flow characteristics. The result of the Span determination using Malvern analysis for Example 1 is shown in Table 1.

In Vitro Inhalation Performance

The dry powder was also characterized using the NEXT GENERATION PHARMACEUTICAL IMPACTOR (NGI), Model 170 (available from MSP Corporation, Shoreview, Minn.). The NGI was equipped with a Copley ventilator set at 60 L/min flow for 4 seconds, to draw the spray dried powder into chambers representing the lungs. NGI data include mass median aerodynamic diameter (MMAD) and fine particle fraction (FPF-NGI stages 3 to 8 representing “deep lungs”, <4.6 μm)—the fraction of particles that would deposit in the deep lungs, or alveoli. The active dose deposited in the lung can be calculated by multiplying the emitted dose (e.g., the dose delivered by an inhalation device) by the fine particle fraction (deposited dose=emitted dose×FPF).

A 15 mg sample of the solid dispersion particles was evaluated using the NGI. The sample was weighed and loaded into a Quali-V HPMC capsule (size #3). In each chamber of the NGI, 3 drops of silicon oil were added and distributed to all surfaces using a Kimwipe. The HPMC capsule was punctured and attached to the NGI mouth. The chambers were rinsed using 10 mL deionized water, and the samples analyzed using HPLC. The results of the NGI evaluation for Example 1 are shown in Table 1.

Differential Scanning Calorimetry (DSC)

DSC was used to measure the glass transition temperature. The solid dispersion samples were equilibrated for a minimum of 14 hours at ambient temperature and <5% RH, and at ambient temperature and 50% RH. Sample pans were crimped and sealed in an environmental chamber, then loaded into a Thermal Analysis Q1000 Differential Scanning calorimeter equipped with an autosampler (available from T_(A) Instruments, New Castle, Del.). The samples were heated by modulating the temperature at ±1.5° C./min, and ramping the temperature up to 200° C. at 2.5° C./min. The sample had a single Tg at 125° C. and no other thermal events, suggesting the composition was amorphous.

TABLE 1 NGI data Malvern Dry Data Example FPF* (%) MMAD** (μm) Span 1 79 2.6 1.62 *FPF—fine particle fraction **MMAD—mass median aerodynamic diameter

Example 2 Active Agent 1: Dextran 10

A dry powder consisting of particles of a solid dispersion of Active Agent 1 was prepared by forming a spray solution containing 1.5 wt % Active 1, 0.5 wt % Dextran 10, and 98.0 wt % water as follows: the active and solvent were combined in a 500 mL flask and mixed to form a clear solution, then the polymer was added to the solution and mixed for 30 minutes.

The spray solution was pressure fed using 30 psi nitrogen pressure feed from a 1 L pressure vessel to a 2-fluid nozzle (Spray Systems 1650 liquid, 120 air cap). Liquid feed was 25 mL/min, and atomizing nitrogen was 3.0 SCFM at 42 psi into an apparatus substantially the same as the apparatus shown in FIG. 1. The inlet nitrogen gas at a flow of 1340 g/min was heated to 151° C. and introduced to the spray dryer. The exit temperature of the drying gas was 55° C. The dried material was pneumatically conveyed through reducing-sized ductwork to a 3-inch outside diameter cyclone. The resulting solid dispersion particles were collected in a 20 mL jar attached to the bottom of the cyclone. The evaporated solvent and drying gas exited the dryer through the top of the cyclone, and were conditioned by a filter and scrubber. The 5.4 g of so-formed solid dispersion particles were then dried under vacuum desiccation at room temperature.

Dispersion particles were characterized using the Malvern Particle Size Analyzer, and the results are shown in Table 2.

In Vitro Inhalation Performance

The dry powder was tested using the NEXT GENERATION PHARMACEUTICAL IMPACTOR (NGI), as described above. The results of the NGI evaluation for Example 2 are shown in Table 2.

Differential Scanning Calorimetry (DSC)

DSC was used to measure the glass transition temperature. The solid dispersion samples were equilibrated for a minimum of 14 hours at ambient temperature and <5% RH, and at ambient temperature and 50% RH, and analyzed as described above. The sample had a single Tg at 123° C. and no other thermal events, suggesting the composition was amorphous.

TABLE 2 Example NGI data Malvern Dry Data SDD FPF* (%) MMAD** (μm) Span 2 74 2.6 1.50 *FPF—fine particle fraction **MMAD—mass median aerodynamic diameter

Examples 3-5 Active Agent 2: Dextran 10

Examples 3-5 were solid dispersions consisting of 70 wt % Active Agent 2 and 30 wt % Dextran 10. To make Examples 3-5, spray solutions containing 2.1 wt % Active 2, 0.9 wt % Dextran 10, and 97.0 wt % 0.01 N hydrochloric acid were formed by combining the active agent and solvent in a 125 mL flask, mixing to form a clear solution, and adding the polymer with stirring. The pH of the spray solution was adjusted to 7.4 using dilute sodium hydroxide. Prior to spray drying, the solution was diluted with water. For Examples 3 and 4, the final solids concentration in the spray solution was 0.2 wt %. For Example 5, the final solids concentration in the spray solution was 0.8 wt %.

To spray dry the dispersions, the spray solutions were pressure fed using 30 psi nitrogen pressure feed from a 1 L pressure vessel to a 2-fluid nozzle (Spray Systems 1650 liquid, 120 air cap). Liquid feed was 12 mL/min for Example 3, and 25 mL/min for Examples 4 and 5. Atomizing nitrogen was 3.4, 3.5, and 3.6 SCFM (Example 3, 4, and 5) at 52, 56, and 60 psi (Example 3, 4, and 5) into an apparatus substantially the same as that shown in FIG. 1. For Example 3, the inlet nitrogen gas (1320 g/min) was heated to 110° C. and introduced to the spray dryer. For Examples 4 and 5, the inlet nitrogen gas (1350 g/min) was heated to 140° C. and introduced to the spray dryer. The exit temperature of the drying gas for Examples 3, 4, and 5 was 55° C. The dried material was pneumatically conveyed through reducing-sized ductwork to a 3-inch OD cyclone. The resulting solid dispersion particles were collected in a 20 mL jar attached to the bottom of the cyclone. The evaporated solvent and drying gas exited the dryer through the top of the cyclone, and were conditioned by a filter and scrubber. The solid dispersion particles were then dried under vacuum desiccation at room temperature.

Dispersion particles were characterized using the Malvern Particle Size Analyzer, and the results are shown in Table 3.

In Vitro Inhalation Performance

The dry powders were tested using the NGI as described above. The results of the NGI evaluation for Examples 3, 4, and 5 are shown in Table 3.

Controls 1 and 2 Active Agent 2: Dextran 10

Controls 1 and 2 were solid dispersions consisting of 70 wt % Active Agent 2 and 30 wt % Dextran 10, spray-dried as described above, except that a conventional spray dryer was used. To make Controls 1 and 2, spray solutions containing 2.1 wt % Active 2, 0.9 wt % Dextran 10, and 97.0 wt % 0.01 N hydrochloric acid were formed as described above for Examples 3-5. The dispersion of Control 1 was spray-dried without dilution (3.0 wt % solids), and the dispersion of Control 2 was spray-dried following dilution of the spray solution by addition of water, for a final solids concentration of 0.8 wt %. The solutions were spray-dried by directing an atomizing spray using a two-fluid external-mix spray nozzle (Spray Systems 1650 liquid, 120 air cap) at a feed rate of 12.5 g/min into the stainless-steel chamber of a spray dryer (a Niro type XP Portable Spray-Drier with a Liquid-Feed Process Vessel (“PSD-1”)), maintained at a temperature of 130° C. at the inlet. The resulting solid dispersions were collected in a cyclone. The dispersions formed using the above procedure were post-dried before further use.

Dispersion particles were characterized using the Malvern Particle Size Analyzer and the NGI, and the results are shown in Table 3. The results in Table 3 show that dispersion particles obtained using the PSD-1 are larger, with a larger span (broader particle size distribution) than dispersion particles obtained using the spray-drying apparatuses disclosed herein. Example 5 and Control 2 provide the closest comparisons, since these dispersions were spray-dried from spray solutions both containing 0.8 wt % solids.

TABLE 3 Malvern Dry Example NGI data Data SDD FPF* (%) MMAD** (μm) Span 3 90 ND 1.32 4 97 ND 1.11 5 88 1.6 1.28 Control 1 82 2.1 1.51 Control 2 62 2.6 1.61 *FPF—fine particle fraction **MMAD—mass median aerodynamic diameter ND—no data

Examples 6 and 7 Active Agent 1: Dextran 10

Examples 6 and 7 were solid dispersions consisting of Active Agent 1 and Dextran 10. To make Example 6, a spray solution was formed containing 0.1 wt % Active 1, 1.9 wt % Dextran 10, and 98.0 wt % water, giving a solid dispersion consisting of 5 wt % Active Agent 1 and 95 wt % Dextran 10. To make Example 7, a spray solution was formed containing 0.2 wt % Active 1, 1.8 wt % Dextran 10, and 98.0 wt % water, giving a solid dispersion consisting of 10 wt % Active Agent 1 and 90 wt % Dextran 10. To spray dry the dispersions, the spray solutions were pressure fed using 30 psi nitrogen pressure feed from a 1 L pressure vessel to a 2-fluid nozzle (Spray Systems 1650 liquid, 120 air cap). Liquid feed was 25 mL/min, and atomizing nitrogen was 3.0 SCFM at 42 psi into an apparatus substantially the same as that shown in FIG. 1. The inlet nitrogen gas (1350 g/min) was heated to 130° C. for Example 6, and 150° C. for Example 7, and introduced to the spray dryer. The exit temperature of the drying gas was 55° C. The dried material was pneumatically conveyed through reducing-sized ductwork to a 3-inch outside diameter cyclone. The resulting solid dispersion particles were collected in a 20 mL jar attached to the bottom of the cyclone. The evaporated solvent and drying gas exited the drier through the top of the cyclone, and were conditioned by a filter and scrubber. The solid dispersion particles were then dried under vacuum desiccation at room temperature.

Dispersion particles were characterized using the Malvern Particle Size Analyzer and the NGI, and the results are shown in Table 4.

TABLE 4 Malvern Dry Example NGI data Data SDD FPF* (%) MMAD** (μm) Span 6 65 2.8 ND 7 69 2.6 2.8 *FPF—fine particle fraction **MMAD—mass median aerodynamic diameter ND—no data

Examples 8 and 9 Active Agent 3: Dextran 10

Examples 8 and 9 were solid dispersions consisting of 70 wt % Active Agent 3 and 30 wt % Dextran 10. To make Example 8, a spray solution containing 2.0 wt % Active 3, 0.9 wt % Dextran 10, and 97.1 wt % water was formed by combining the active and solvent in a 125 mL flask, mixing to form a clear solution, and adding the polymer with stifling. The pH of the spray solution was adjusted to 6.4 using dilute sodium hydroxide. Prior to spray drying, the solution was diluted to 1.5 wt % solids with water. To make Example 9, a spray solution containing 1.0 wt % Active 3, 0.4 wt % Dextran 10, and 98.6 wt % water was formed by combining the active and solvent in a 125 mL flask, mixing to form a clear solution, and adding the polymer with stirring. The pH of the spray solution was adjusted to 6.6 using dilute sodium hydroxide. There was no dilution of the spray solution prior to spray drying. To spray dry the dispersions, the spray solutions were pressure fed using 30 psi nitrogen pressure feed from a 1 L pressure vessel to a 2-fluid nozzle (Spray Systems 1650 liquid, 120 air cap). Liquid feed was 25 mL/min, and atomizing nitrogen was 3.3 SCFM at 45 psi into an apparatus substantially the same as that shown in FIG. 1. The inlet nitrogen gas (1350 g/min) was heated to 143° C. for Example 8, and 118° C. for Example 9, and introduced to the spray dryer. The exit temperature of the drying gas was 55° C. The dried material was pneumatically conveyed through reducing-sized ductwork to a 3-inch outside diameter cyclone. The resulting solid dispersion particles were collected in a 20 mL jar attached to the bottom of the cyclone. The evaporated solvent and drying gas exited the drier through the top of the cyclone, and were conditioned by a filter and scrubber. The solid dispersion particles were then dried under vacuum desiccation at room temperature.

Dispersion particles were characterized using the NGI, and the results are shown in Table 5.

TABLE 5 Example NGI data SDD FPF* (%) MMAD** (μm) 8 80 2.06 9 80 1.84 *FPF—fine particle fraction **MMAD—mass median aerodynamic diameter

FIG. 9 illustrates an embodiment of a method and system configured for introducing spray solutions at elevated temperatures into a drying chamber. FIG. 9 illustrates the drying chamber 40 of spray-drying apparatus 110 as being generally cylindrical. However, the drying chamber may take any other cross-sectional shape suitable for spray drying a spray solution, including square, rectangular, and octagonal, among others. The spray-drying apparatus 110 is also depicted as having one nozzle 50. However, multiple nozzles can be included in the spray-drying apparatus to achieve higher throughput of the spray solution.

Referring to FIG. 9, apparatus 110 includes a feed suspension tank 20, a heat exchanger 30, a drying chamber 40, a nozzle 50, and a particle-collection means 60. In one embodiment, the process is performed as follows. An active agent and a matrix material are combined with a solvent in the feed suspension tank 20 to form a feed suspension. The solvent can be an organic solvent. The feed suspension is at a temperature T₁, which is below the ambient-pressure boiling point of the solvent. Temperature T₁ is also below either T_(A), the temperature at which the active agent solubility equals the active agent concentration in the solvent at equilibrium, or T_(M), the temperature at which the matrix material solubility equals the matrix material concentration in the solvent at equilibrium. One of ordinary skill will understand that several factors affect dissolution of an active agent and a matrix material in a solvent, including the solute particle size, the flow conditions of the suspension, and the residence time of the solute particles in the solvent at T_(A) or T_(M). At least a portion of the active agent, a portion of the matrix material, or a portion of both the active agent and the matrix material are suspended, that is not dissolved, in the solvent. An optional mixing means 22 may be used to keep the feed suspension homogeneous while processing. When the solvent is flammable, oxygen is normally excluded from all parts of the drying apparatus. In particular, an inert gas, such as nitrogen, helium, argon, and the like, is often used to fill the void space in the feed suspension tank for safety reasons.

For convenience, the feed suspension can be maintained at near-ambient temperatures; however, this is not a limitation of the disclosed processes. Generally, the temperature of the feed suspension, T₁, can range from 0° C. to 50° C. or even higher. Temperatures of less than 0° C. may also be utilized, especially when there are stability concerns about the active agent.

The feed suspension in the feed suspension tank 20 is delivered to a pump 24, which directs the feed suspension to a heating device, such as heat exchanger 30. Heat exchanger 30 has a feed suspension inlet 26, a spray solution outlet 36, a heating fluid inlet 32, and a heating fluid outlet 34. In the heat exchanger 30, the feed suspension enters through the feed suspension inlet 26 at temperature T₁, and exits as the spray solution through the spray solution outlet 36 at temperature T₂. Spray solution temperature T₂ is greater than feed suspension temperature T₁. To prevent unwanted vaporization/boiling of the solvent in the spray solution, pump 24 increases the pressure of the spray solution such that the pressure of the spray solution at spray solution outlet 36 is greater than the vapor pressure of the solvent at temperature T₂. The temperature of the spray solution when it enters the nozzle 50 is generally near T₂. Preferably it is within 30° C. of temperature T₂. In addition, T₂ is greater than or equal to the lesser of T_(A) and T_(M). In one embodiment, T₂ is greater than or equal to the greater of T_(A) and T_(M). When it is the object of the process to form a solid amorphous dispersion of the active agent and the matrix material, T₂ is greater than or equal to T_(A). Preferably, T₂ is at least 10° C. greater than T_(A). In one embodiment, the spray solution temperature T₂ is greater than the ambient-pressure boiling point of the solvent.

The spray solution exiting the heat exchanger may be at any temperature, T₂, which is greater than T₁, as long as T₂ is greater than or equal to the lesser of T_(A) and T_(M). Temperature T₂ may be at least 10° C. greater than T₁, at least 20° C. greater than T₁, at least 30° C. greater than T₁, at least 40° C. greater than T₁, or even at least 50° C. greater than T₁. In one embodiment, temperature T₂ is at least 50° C. In another embodiment, temperature T₂ is at least 70° C. In another embodiment, temperature T₂ is at least 80° C. In another embodiment, temperature T₂ is at least 90° C. In another embodiment, T₂ is at least 100° C. In still another embodiment, T₂ is at least 120° C.

In one embodiment, the active agent and the matrix material are both essentially completely dissolved in the solvent at temperature T₂. By “essentially completely dissolved” is meant that less than 5 wt % of the solute remains undissolved. In the case of matrix materials, the term “dissolved” can take a broader definition. For some matrix materials, such as polymers, the term dissolved can mean the polymer has gone into solution, or it can mean the polymer is dispersed or highly swollen with the solvent such that it acts as if it were in solution. In contrast, at temperature T₁, at least one of the active agent and the matrix material are present as a suspension in the solvent. Any suitable technique may be used to determine if the active agent and matrix material are soluble in the solvent at temperature T₂. Examples include dynamic or static light scattering analysis, turbidity analysis, and visual observations. In one embodiment, the spray solution comprises the active agent and the matrix material dissolved in the solvent at temperature T₂.

In one embodiment, temperature T₂ is greater than the temperature at which the active agent and matrix material are soluble in the solvent. That is, T₂ is greater than or equal to the greater of T_(A) and T_(M). It may be desirable that temperature T₂ be much greater than the greater of T_(A) and T_(M). Thus, temperature T₂ may be at least 10° C. greater than the greater of T_(A) and T_(M), at least 20° C. greater than the greater of T_(A) and T_(M), or even at least 30° C. greater than the greater of T_(A) and T_(M). Spray-dried products made by embodiments of the disclosed processes are typically more uniform and homogeneous when temperature T₂ is greater than the greater of T_(A) and T_(M).

In one embodiment, the pump 24 increases the pressure of the spray solution to a pressure ranging from 2 atm to 400 atm. In another embodiment, the pressure of the spray solution as it exits the heat exchanger 30 is greater than 10 atm.

The heat exchanger 30 may be of any design wherein heat is transferred to the feed suspension resulting in an increase in temperature. In one embodiment, the heat exchanger 30 is an indirect heat exchanger, wherein a heating fluid is in contact with the feed suspension through a heat-transfer surface. Exemplary indirect heat exchangers include tube-in-tube devices and tube-in-shell devices, both well-known in the art. The heat exchanger 30 may also be a direct heat exchanger, in which a heating fluid, such as steam, is injected directly into the feed suspension, resulting in an increase in the temperature of the feed suspension. In yet another embodiment, the feed suspension flows over a hot surface, such as a resistance heating element, resulting in an increase in temperature of the feed suspension. Other heating sources may also be used, such as microwaves and ultrasonic devices that can increase the temperature of the feed suspension.

The concentration of active agent and matrix material in the spray solution can be virtually any value. In one embodiment, the concentration of total solids (that is, active agent and matrix material) in the solvent is at least 0.5 wt %. The concentration of total solids in the solvent may be at least 1 wt %, at least 5 wt %, or even at least 10 wt % or more. In another embodiment, the concentration of active agent in the solvent is at least 1.25-fold the solubility of the active agent in the solvent at temperature T₁. The concentration of active agent in the solvent may be at least 1.5-fold, at least 2.0-fold, or even 2.5-fold or more the solubility of the active agent in the solvent at temperature T₁.

In one embodiment, the residence time of the feed suspension in the heat exchanger 30 is minimized so as to limit the time the suspension/solution is exposed to elevated temperatures. The residence time of the suspension/solution in the heat exchanger may be less than 30 minutes, less than 20 minutes, less than 10 minutes, less than 5 minutes, or even less than 1 minute.

The spray solution at the spray solution outlet 36 is directed to a drying chamber 40, where it enters a nozzle 50 for atomizing the spray solution into droplets 44. The temperature of the spray solution when it enters the nozzle 50 is the spray temperature, designated as T₃. When it is desired to keep the active agent and matrix material dissolved in the spray solution, it is often desirable for T₃ to be at or near T₂. However, there are sometimes advantages to having T₃ significantly less than T₂. For example, degradation of the active agent may be reduced or atomization in certain nozzles may be more effective when T₃ is significantly less than T₂. In some cases, it is even desirable for T₃ to be sufficiently low that the active agent, the matrix material, or both the active agent and the matrix material are not soluble in the solvent. In such cases, the solution may be below the point at which the solutes are soluble for a sufficiently short time such that all the solutes remain in solution until the solution is atomized. Alternatively, the solution may be below the point at which the solutes are soluble for a sufficiently long time that one or more of the matrix material or the active agent may precipitate or crystallize from solution. In one embodiment, temperature T₃ is less than 5° C. less than T₂. In another embodiment, temperature T₃ is less than 20° C. less than T₂. In another embodiment, temperature T₃ is less than 50° C. less than T₂. In still another embodiment, both temperatures T₂ and T₃ are greater than the greater of T_(A) and T_(M). In one embodiment, temperatures T₂ and T₃ are at least 5° C. greater than the greater of T_(A) and T_(M). In another embodiment, temperatures T₂ and T₃ are at least 20° C. greater than the greater of T_(A) and T_(M). In yet another embodiment, temperatures T₂ and T₃ are at least 50° C. greater than the greater of T_(A) and T_(M).

In one embodiment, the apparatus 110 is designed such that the time the spray solution is at a temperature greater than T₃ is minimized. This may be accomplished by locating the spray solution outlet 36 as close as possible to the nozzle 50. Alternatively, the size of the tubing or fluid connections between the spray solution outlet 36 and the nozzle 50 may be small, minimizing the volume of spray solution and reducing the time the spray solution is at a temperature greater than T₃. The time the spray solution is at a temperature greater than T₃ may be less than 30 minutes, less than 20 minutes, less than 10 minutes, less than 5 minutes, or even less than 1 minute.

Virtually any nozzle can be used to atomize the spray solution into droplets. The inventors have found that pressure nozzles are effective in embodiments of the disclosed processes. In another embodiment, a flash nozzle is used, as described below.

The drying chamber 40 also has a source of heated drying gas 42 which is combined with the droplets 44 in the drying chamber 40. In the drying chamber 40, at least a portion of the solvent is removed from the droplets to form a plurality of particles comprising the active agent and the matrix material. Generally, it is desired that the droplets are sufficiently dry by the time they come in contact with the drying chamber surface that they do not stick or coat the chamber surfaces.

The particles, along with the evaporated solvent and drying gas, exit the drying chamber at outlet 46, and are directed to a particle-collection means 60. Suitable particle-collection means include cyclones, filters, electrostatic particle collectors, and the like. In the particle-collection means 60, the evaporated solvent and drying gas 62 are separated from the plurality of particles 66, allowing for collection of the particles.

The particles may be of any desired size. In one embodiment, the particles have an average diameter ranging from 0.5 μm to 500 μm. In another embodiment, the particles have a diameter ranging from 0.5 μm to 100 μm. In another embodiment, the particles have an average diameter of greater than 10 μm. In still another embodiment, the particles have an average diameter of greater than 20 μm. In still another embodiment, the particles have an average diameter of greater than 30 μm. In yet another embodiment, the particles have a mass median aerodynamic diameter ranging from 0.5 μm to 10 μm. In still another embodiment, the particles have a mass median aerodynamic diameter ranging from 1 μm to 5 μm.

In one embodiment, the concentration of solvent remaining in the particles when they are collected (that is, the concentration of residual solvent) is less than 10 wt % based on the total weight of the particles. In another embodiment, the concentration of residual solvent in the particles when they are collected is less than 5 wt %. In yet another embodiment, the concentration of residual solvent in the particles is less than 3 wt %. In another embodiment, a drying process subsequent to the spray-drying process may be used to remove residual solvent from the particles. Exemplary processes include tray drying, fluid-bed drying, vacuum drying, and the drying processes described in WO2006/079921 and WO2008/012617.

In one embodiment, nozzle 50 is a flash nozzle 50 a. There is shown in FIG. 10 a cross-sectional schematic of a flash nozzle 50 a. Flash nozzle 50 a consists of a central tube 51 and an outer tube 53. Central tube 51 is in fluid communication with the inflowing spray solution 55, while outer tube 53 is in fluid communication with a sweep gas 52. The flash nozzle 50 a has an inlet end, represented by A, and an outlet end, represented by B. The spray solution 55 from the heat exchanger 30 (not shown in FIG. 10) enters central tube 51 at A. A sweep gas 52 enters outer tube 53 at A. As spray solution 55 travels through the central tube 51 from inlet A to outlet B, the pressure decreases due to pressure drop. Between the inlet A and outlet B, the pressure of the spray solution 55 decreases to a value that is less than the vapor pressure of the solvent in the spray solution, leading to the formation of vapor bubbles of the solvent (a process known as cavitation). By the time the spray solution 55 reaches outlet B of the central tube 51, it is a fluid 56 comprising droplets of spray solution and vapor-phase solvent. In one embodiment, the central tube 51 is coated with a non-stick coating. In another embodiment, the outer tube 53 is coated with a non-stick coating. In still another embodiment, the central tube 51 and the outer tube 53 are coated with a non-stick coating. Non-stick coatings include, for example, polytetrafluoroethylene (PTFE) or other suitable non-stick coatings.

The sweep gas 52 exiting through the outer tube outlet 58 is in fluid communication with the fluid 56 exiting through the central tube 51. The sweep gas 52 decreases the likelihood that solid material will form at the exit from the central tube 51 or the outer tube 53.

The processes described herein can be used to form a composition comprising an active agent. The active agent can be highly water soluble, sparingly water soluble, or poorly water soluble. In one embodiment, the active agent is “poorly water soluble,” meaning that the active agent has a solubility in water (over the pH range of 6.5 to 7.5 at 25° C.) of less than 5 mg/mL. The active agent may have an even lower aqueous solubility, such as less than about 1 mg/mL, less than about 0.1 mg/mL, and even less than about 0.01 mg/mL.

The processes disclosed herein can also be used to form compositions comprising a matrix material. Matrix materials suitable for use in the compositions formed by the disclosed methods should be inert, in the sense that they do not chemically react with the active agent in an adverse manner. The matrix material can be neutral or ionizable. In one embodiment, the composition includes two or more matrix materials.

Exemplary matrix materials include polysaccharides. Polysaccharides can be underivatized, such as cellulose, starch, dextran, pullulan, dextrin, maltodextrin, glycogen, inulin, fructan, mannan, chitin, polydextrose, fleximer (a ring-opened form of dextran), and oligosaccharides. Often, derivatives and substituted versions of the polysaccharides are preferred. Examples of such polysaccharide derivatives include ester- and ether-linked derivatives. Included in this class are cellulose ethers, cellulose esters, and cellulose derivatives that have both ester and ether substituents. Specific examples include cellulose acetate, ethyl cellulose, hydroxypropyl methyl cellulose and hydroxyethyl cellulose. Starch derivatives include starch acetate and carboxymethyl starch. Also included are synthetic matrix materials, such as polyacrylates and polymethacrylates, vinyl matrix materials, polyethylenes, polyoxyethylenes, polypropylenes, polyamides, polyesters, polycarbonates, and derivatives and substituted versions thereof; copolymers of various types, including random and block copolymers; other matrix materials such as lactose, trehalose, sucrose, fructose, maltose, dextrose, xylitol, sorbitol, glycine, amino acids, citric acid, phospholipids, bile salts; and mixtures thereof.

In one embodiment, the matrix material is amphiphilic, meaning that the matrix material has hydrophobic and hydrophilic portions. In another embodiment, the matrix material is ionizable.

In yet another embodiment, the matrix material comprises a polymer. Appropriate matrix polymers include polyvinylpyrrolidone, vinyl acetate/vinylpyrrolidone copolymers, vinyl alcohol, vinyl acetate/vinyl alcohol copolymers, hydroxyethyl cellulose, hydroxypropyl methylcellulose, hydroxypropyl methylcellulose phthalate, carboxymethyl cellulose, carboxymethyl ethylcellulose, hydroxypropyl methylcellulose acetate succinate, cellulose acetate phthalate and cellulose acetate trimellitate. In still another embodiment, the matrix material comprises an ionizable cellulosic polymer. In yet another embodiment, the matrix material comprises an amphiphilic, ionizable polymer.

In one embodiment, the matrix material is biodegradable, meaning that the matrix material will degrade over time. By “degrade” is meant that in a use environment, the matrix material is broken down into smaller species that can be absorbed, metabolized, or otherwise eliminated or removed from the environment of use. This degradation can occur through enzymatic, hydrolytic, oxidative, or other reaction, as is well known in the art, or by degrading the matrix material into aqueous soluble species that can readily be removed from the environment of use.

In one embodiment, the composition made by the disclosed processes is in the form of a solid amorphous dispersion of the active agent and the matrix material.

In another embodiment, the particles comprise a solid amorphous dispersion of the active agent and matrix material consisting essentially of amorphous active agent molecularly dispersed throughout the matrix material. In this embodiment, the solid dispersion may be considered a “solid solution” of active agent and matrix material. The term “solid solution” includes both thermodynamically stable solid solutions in which the active agent is completely dissolved in the matrix material, as well as homogeneous materials consisting of amorphous active agent molecularly dispersed throughout the matrix material in amounts greater than the solubility of the active agent in the matrix material. A dispersion is considered a “solid solution” when it displays a single glass-transition temperature when analyzed by differential scanning calorimetry (DSC). In one embodiment, the particles have at least one Tg due to the amorphous character of the matrix material. In another embodiment, at least 90 wt % of the active agent in the particles is amorphous. In yet another embodiment, the active agent is amorphous and molecularly dispersed in a portion of one or more of the matrix materials, while the remaining portion of the matrix materials is present as a separate phase. This separate phase matrix material may be amorphous, crystalline, or a mixture of both amorphous and crystalline.

In another embodiment the particles comprise the active agent in crystalline form, which is homogeneously or substantially homogeneously distributed in the matrix material. In still another embodiment, the particles comprise the active agent in amorphous or non-crystalline form, which is homogeneously distributed in the matrix material matrix. In yet another embodiment, the particles comprise a mixture of active agent in crystalline and amorphous forms homogeneously distributed in the matrix material.

In still another embodiment, the particles comprise a mixture of active-agent-rich domains and matrix material-rich domains. The active agent in the domains may be amorphous, crystalline, or a mixture of amorphous and crystalline.

In yet another embodiment, the compositions comprise a third component in addition to the active agent and the matrix material. This third component may be any compound or mixture of compounds that facilitates the intended use of the disclosed compositions. Exemplary third components include, but are not limited to, matrix materials, surface active agents, wetting agents, diluents, fillers, bulking agents, disintegrants, flavors, fragrances, buffering agents, and/or other components known in the art.

Examples 10-11

Active Agent 1 was S-(fluoromethyl) 6α,9-difluoro-11β,17-dihydroxy-16α-methyl-3-oxoandrosta-1,4-diene-17β-carbothioate, 17-propionate, also known as fluticasone propionate, having the structure:

Active Agent 1 has a solubility of 0.4 μg/mL in pH 7.4 buffer, and a Log P value of 3.7. The Tg of amorphous Active Agent 1 was determined by DSC to be 84° C. The room temperature (20° C. to 30° C.) solubility of Active Agent 1 in methanol is 0.3 wt %.

Example 10

A spray-dried dispersion was made using an apparatus similar to that shown in FIG. 9. A feed suspension was prepared by mixing 3 gm of Active Agent 1 and 9 gm of the MG grade of hydroxypropyl methylcellulose acetate succinate (HPMCAS-MG, AQOAT-MG available from Shin Etsu, Tokyo, Japan) with 88 gm of a methanol solvent. The HPMCAS-MG dissolved in the solvent, while the active agent remained in suspension. The feed suspension was maintained at ambient temperature, 20° C. to 30° C., with stifling in a pressure pot to prevent settling of the particles of Active Agent 1. The total solids content of the feed suspension was 12 wt %.

The feed suspension in the pressure pot was pressurized to 245 psig and directed at a rate of 26 gm/min to a tube-in-shell heat exchanger. Heating fluid at 160° C. was circulated in a countercurrent manner through the heat exchanger. The spray solution exiting the heat exchanger was at a temperature, T₂, of 120° C., and all of the active agent and matrix material were dissolved in the spray solution. The average residence time of the spray solution in the heat exchanger was less than 60 seconds. The total time the spray solution was at a temperature of 120° C. was less than 80 seconds. Thus, the elapsed time from the time the spray solution exited the heat exchanger to the time it exited the pressure nozzle was 20 seconds. The temperature of the nozzle was 120° C.

The spray solution was delivered to the spray-drying chamber where it was atomized using a Schlick 2.0 pressure nozzle (Diisen-Schlick GmbH of Untersiemau, Germany). The spray solution was atomized into droplets within the spray-drying chamber, while simultaneously mixing the droplets with a nitrogen drying gas which was introduced to the drying chamber at a temperature of 140° C. and at a flow rate of 520 gm/min, resulting in the formation of solid particles.

The solid particles, along with the evaporated solvent and the drying gas, were directed to a cyclone separator, where the solid particles were collected. The particles were subsequently dried in a vacuum chamber at 0.15 atm for 2 to 3 hours to remove residual methanol from the particles.

The resulting particles had 25 wt % Active Agent 1 in HPMCAS-MG.

Control 1

As a control, a 25 wt % Active Agent 1 in HPMCAS-MG composition was made using a conventional ambient-temperature spray-drying process. For Control 1, a feed solution was formed by dissolving 0.45 gm of Active Agent 1 and 1.35 gm of HPMCAS-MG in 179.7 gm methanol. Both the active agent and the matrix material completely dissolved in the methanol at ambient temperature. The total solids content of this solution was 1.0 wt %.

This solution was spray dried using the same apparatus as described for Example 1, except that the heat exchanger was bypassed, such that the spray solution was not heated prior to atomization. All other operating variables were nominally the same as described in Example 1.

Control 2

As a second control, a feed suspension similar to that formed for Example 1 was prepared and then spray dried without heating the spray solution. The feed suspension consisted of 2.25 gm of Active Agent 1, 6.75 gm of HPMCAS-MG, and 66 gm of methanol, resulting in a feed suspension containing 12 wt % solids. Because the feed was a suspension rather than a solution, a two-fluid nozzle was used (manufactured by Spray Systems, Wheaton, Ill.) to avoid clogging.

The feed suspension was spray dried using the same apparatus as described for Example 1, except that the heat exchanger was bypassed, such that the spray solution was not heated prior to atomization, and a two-fluid nozzle was used for atomization of the feed. All other operating variables were nominally the same as described in Example 1.

Analysis of Compositions from Example 10, Control 1, and Control 2

Samples of the compositions of Example 10, Control 1, and Control 2 were analyzed by powder X-ray diffraction using an AXS D8 Advance PXRD measuring device (Bruker, Inc. of Madison, Wis.). Samples (approximately 100 mg) were packed in Lucite sample cups fitted with Si(511) plates as the bottom of the cup to give no background signal. Samples were spun in the φ plane at a rate of 30 rpm to minimize crystal orientation effects. The x-ray source (KCu_(α), λ=1.54 Å) was operated at a voltage of 45 kV and a current of 40 mA. Data for each sample were collected over a period of 27 minutes in continuous detector scan mode at a scan speed of 1.8 seconds/step and a step size of 0.04°/step. Diffractograms were collected over the 28 range of 4° to 40°.

FIG. 11 shows the results of this analysis. The composition of Example 10, made using a concentrated feed suspension and a heat exchanger to increase the feed temperature according to the disclosed processes, showed an amorphous halo, indicating the active agent in the composition was amorphous. Likewise, the composition of Control 1, made using a conventional spray-drying process using a dilute spray solution of active agent and matrix material dissolved in a solvent at ambient temperature, also showed only an amorphous halo. However, the composition of Control 2, made using a concentrated feed suspension but not heated, showed a large number of well-defined peaks, indicating the presence of crystalline active agent in the composition.

This analysis shows that the compositions of Example 10 and Control 1 had similar properties. However, because the spray solution for Example 1 contained 12 wt % solids, while the spray solution for Control 1 only contained 1 wt % solids, certain embodiments of the disclosed processes (Example 10) had a throughput that was 12-fold greater than that of the conventional spray-drying process.

Example 11

A spray-dried dispersion is made using an apparatus similar to that shown in FIG. 9 using the procedures outlined in Example 11, except that the flash nozzle of FIG. 10 is used. The resulting particles consist of 25 wt % Active Agent 1 in HPMCAS.

In one embodiment, the disclosed spray-drying processes comprises delivering a spray solution comprising an active agent and a matrix material in an organic solvent to a spray-drying apparatus, atomizing the spray solution into droplets within the spray-drying apparatus via a nozzle to remove at least a portion of the organic solvent from the droplets to form a plurality of particles, and collecting the particles. The spray solution is delivered to the nozzle at a temperature T₃. The spray solution is formed by forming a feed suspension comprising the active agent, the matrix material and the organic solvent, wherein the feed suspension is at a temperature T₁, and directing the feed suspension to a heat exchanger, thereby increasing the temperature of the feed suspension to a temperature T₂. Temperature T₂ is greater than temperature T₁, and the spray solution is at a pressure that is greater than the vapor pressure of the solvent at temperature T₂, such that the active agent and the matrix material are soluble in the solvent at temperature T₂. In one embodiment, the temperature T₂ is greater than the ambient-pressure boiling point of the solvent.

In any or all of the disclosed embodiments, the active agent and the matrix material may be soluble in the solvent at temperature T₃. In any or all of the disclosed embodiments, the spray solution may be atomized using a flash nozzle.

In any or all of the disclosed embodiments, the temperature T₂ may be at least 100° C. In any or all of the disclosed embodiments, the spray solution may be at temperature T₂ for less than 10 minutes. Alternatively, the spray solution may be at temperature T₂ for less than 5 minutes.

In any or all of the disclosed embodiments, the organic solvent is selected from methanol, ethanol, n-propanol, isopropanol, butanol acetone, methyl ethyl ketone, methyl isobutyl ketone, ethyl acetate, propyl acetate, tetrahydrofuran, acetonitrile, methylene chloride, toluene, 1,1,1-trichloroethane, and mixtures thereof. In certain embodiments, the organic solvent is selected from the group consisting of methanol, ethanol, n-propanol, isopropanol, butanol acetone, methyl ethyl ketone, methyl isobutyl ketone, ethyl acetate, propyl acetate, tetrahydrofuran, acetonitrile, methylene chloride, toluene, 1,1,1-trichloroethane, and mixtures thereof. In any or all of the disclosed embodiments, the organic solvent may contain less than 50 wt % water.

In any or all of the disclosed embodiments, the particles may have a mass median aerodynamic diameter ranging from 0.5 μm to 10 μm. In any or all of the disclosed embodiments, the particles may have an average diameter of greater than 10 μm.

In any or all of the disclosed embodiments, the matrix material may comprise a polymer. In some embodiments, the particles comprise a solid amorphous dispersion of the active agent in the polymer.

Also disclosed are embodiments of products made by any or all of the above processes. In some embodiments, the product comprises a solid amorphous dispersion of the active agent and the polymer.

An embodiment of a process for producing a composition comprises forming a feed suspension comprising an active agent, a matrix material and an organic solvent, wherein the feed suspension is at a temperature T₁, forming a spray solution by directing the feed suspension to a heat exchanger, thereby increasing the temperature of the feed suspension to a temperature T₂, wherein temperature T₂ is greater than temperature T₁, the spray solution is at a pressure that is greater than the vapor pressure of the solvent at temperature T₂, and the active agent and the matrix material are soluble in the solvent at temperature T₂, directing the spray solution to a spray-drying apparatus, the spray-drying apparatus comprising a drying chamber, a nozzle for atomizing the spray solution into droplets, and a source of heated drying gas for removing at least a portion of the organic solvent from the droplets, atomizing the spray solution into droplets in the drying chamber by the nozzle, wherein the spray solution is delivered to the nozzle at a temperature T₃, contacting the droplets with the heated drying gas to remove at least a portion of the organic solvent from the droplets to form a plurality of particles comprising the active agent and the matrix material, and collecting the particles. In some embodiments, the temperature T₂ is greater than the ambient-pressure boiling point of the solvent.

In the disclosed embodiments, the active agent and the matrix material may be soluble in the solvent at temperature T₃. Alternatively, the active agent or the matrix material may not be soluble in the solvent at temperature T₃.

The various methods and systems, or portions thereof, described with reference to FIGS. 1-8 can also be used in combination with the methods and systems, or portions thereof, described with reference to FIGS. 9-11. For example, as shown in FIG. 12, a spray-drying apparatus 210 includes a drying chamber 40 of the type disclosed in FIGS. 1-8 and a heating device 30 of the type disclosed in FIGS. 9-11. The structure and operation of spray-drying apparatus 210 are described below; however, it should be understood that certain aspects of spray-drying apparatus 210 are common to other spray-drying apparatuses described herein and therefore the description of those aspects may not be repeated. Accordingly, unless one of ordinary skill in the art would understand otherwise in view of FIG. 12 and its related description, the descriptions herein of other embodiments of spray-drying apparatuses are also generally applicable to spray-drying apparatus 210.

As shown in FIG. 12, apparatus 210 includes a feed suspension tank 20, a heat exchanger 30, a drying chamber 40, a nozzle 50, and a particle-collection means 60. The feed suspension in the feed suspension tank 20 can be delivered to a pump 24, which directs the feed suspension to a heating device, such as heat exchanger 30. Heat exchanger 30 has a feed suspension inlet 26, a spray solution outlet 36, a heating fluid inlet 32, and a heating fluid outlet 34. The feed suspension enters heat exchanger 30 through the feed suspension inlet 26 at temperature T₁, and exits as a spray solution through the spray solution outlet 36 at temperature T₂.

In the embodiment shown in FIG. 12, the spray solution is directed into a drying chamber 40 of the type described with reference to FIGS. 1-8. The spray solution enters nozzle 50, which atomizes the spray solution into droplets 44. The drying chamber 40 has a first end 70, a second end 72, and at least one side wall 48 extending between the first end 70 and second end 72 to define an interior of the drying chamber 40. As shown in FIG. 12, nozzle 50 can be positioned at first end 70 and at least a portion of the side wall(s) 48 can extend away from a center axis of the drying chamber 40 at a first angle relative to the center axis (see, e.g., FIG. 2).

The first angle can be between 5 degrees and 45 degrees. In addition, in some embodiments, a ratio of the length between the first and second ends of the drying chamber to a maximum width between opposing internal surfaces of the interior of the drying chamber 40 can be at least 5 to 1. Nozzle 50 is configured to atomize the spray solution into the drying chamber 40 at a maximum spray pattern angle relative to the center axis of the drying chamber 40 that is less than 45 degrees. Additional suitable structures and more specific and/or different suitable ranges are disclosed in more detail above in connection with the embodiments shown in FIGS. 1-11.

In some embodiments, an active agent and a matrix material can be combined with a solvent in the feed suspension tank 20 to form a feed suspension. As described herein, the solvent can be an organic solvent.

In some embodiments, nozzle 50 can comprise a flash nozzle as described above with respect to FIG. 10 and as described below in Example 12. The flash nozzle utilizes a pressure drop that induces cavitation in the spray solution prior to exiting the nozzle orifice to induce droplet formation. A sweep gas around the orifice is used to eliminate or reduce solids build-up during operation.

By combining elements of a spray dryer that is capable of exhibit low residence times for spray-dried particles (i.e., FIGS. 1-8) with an elevated temperature spray dryer (i.e., FIGS. 9-11), the resulting spray-drying apparatus 210 and methods of using the same can reduce unnecessary circulation of spray-drying particles, minimize residence times in the drying chamber, and allow spray solutions to be elevated to temperatures that can improve various aspects of the spray solution, such as improved solubility by heating the spray solution to a temperature above which most or all components of the solution are dissolvable.

Example 12

A composition was made using an apparatus similar to that shown in FIG. 12. A 5 wt % feed suspension was prepared by mixing 75 g of dextran having a starting average molecular weight of 5000 Daltons, then substituted with propionate and succinate groups (D5PS), with 1425 g of acetone in a feed suspension tank. The feed suspension was maintained at ambient temperature with stifling to prevent settling of the particles. The feed suspension was pumped to a heat exchanger, entering the heat exchanger at ambient temperature, and exiting the heat exchanger at 135° C. as the spray solution.

The spray solution was delivered to the spray drying apparatus similar to that shown in FIG. 12. The spray solution was delivered to the spray drier at a rate of 39 g/min at a pressure of 735 psig. The spray solution was atomized using a flash nozzle having an inside diameter of 170 μm, an outside diameter of 1588 μm, and a length of 50 mm, inserted into a 0.3-mm diameter tube, similar to the nozzle shown in FIG. 10; nitrogen was flowing through the outer tube at a flow rate such that the nitrogen pressure in the outer tube was 10 psig. Nitrogen drying gas entered the drying chamber at a flow rate of 1630 g/min and an inlet temperature of 67° C. The evaporated solvent and drying gas exited the spray drier at a temperature of 47° C. The resulting composition was collected in a cyclone.

The particles were characterized using a Malvern Particle Size Analyzer, available from Malvern Instruments Ltd. of Framingham, Mass. The mean diameter is reported as D(3,2) (the sum of diameters cubed over the sum of diameters squared). The data obtained includes D₁₀, the diameter corresponding to the diameter of particles that make up 10% of the total volume containing particles of equal or smaller diameter, D₅₀, and D₉₀. Another parameter is “Span,” a dimensionless parameter indicative of the uniformity of the particle size distribution, defined as

${Span} = \frac{D_{90} - D_{10}}{D_{50}}$

Generally, the lower the Span, the more narrow the particle size distribution, resulting in improved flow characteristics. The results of the particle characterization for Example 12 are shown in Table 6.

Examples 13-15

In Examples 13-15, particles were spray-dried as described in Example 12, with the following exceptions. For Example 13, a flash nozzle was used having an inside diameter of 250 μm, an outside diameter of 1588 μm, and a length of 50 mm, inserted into a 0.3-mm diameter tube; nitrogen was flowing through the outer tube at a flow rate such that the nitrogen pressure in the outer tube was 40 psig. The feed solution flow was 123 g/min at a pressure of 730 psig, and the nitrogen drying gas flow was 1350 g/min at 110° C. The evaporated solvent and drying gas exited the spray drier at a temperature of 48° C.

For Example 14, a flash nozzle was used having an inside diameter of 380 μm, an outside diameter of 1588 μm, and a length of 50 mm, inserted into a 0.3-mm diameter tube; nitrogen was flowing through the outer tube at a flow rate such that the nitrogen pressure in the outer tube was 10 psig. The feed solution flow was 208 g/min at a pressure of 680 psig, and the drying gas nitrogen flow was 1370 g/min at 100° C. The evaporated solvent and drying gas exited the spray drier at a temperature of 46° C.

For Example 15, a 10 wt % spray suspension was made by mixing 30.3 g of D5PS, with 273 g of acetone. The flash nozzle of Example 14 was used, the feed solution flow was 200 g/min at a pressure of 605 psig, and the drying gas nitrogen flow was 1650 g/min at 114° C. The evaporated solvent and drying gas exited the spray drier at a temperature of 47° C.

The results of the particle characterization analysis for the particles formed in Examples 12-15 are shown in Table 6.

TABLE 6 Particle Properties Example D(3, 2) (μm) D₁₀ (μm) D₅₀ (μm) D₉₀ (μm) Span 12 2.1 1.3 2.4 4.6 1.4 13 2.2 1.3 2.5 4.6 1.4 14 2.3 1.3 2.6 5.3 1.5 15 2.3 1.3 2.7 6.1 1.8

In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims. 

We claim:
 1. A method of spray drying, comprising: forming a plurality of droplets by atomizing a spray solution using a nozzle positioned at the first end of the drying chamber, the drying chamber further comprising a second end and at least one side wall extending between the first and second ends to define an interior of the drying chamber and having a center axis, wherein at least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from the center axis at a first angle relative to the center axis, the first angle being at least 5° but less than 45°, and wherein a ratio of the length between the first and second ends to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1; delivering the plurality of droplets into the drying chamber; delivering drying gas into the drying chamber to at least partially dry the plurality of droplets to form a plurality of particles; and directing the plurality of particles out of the drying chamber; wherein the spray solution is initially at a temperature T₁ and is directed to a heat exchanger to increase the temperature of the spray solution to temperature T₂ prior to atomization of the spray solution, wherein temperature T₂ is greater than temperature T₁; wherein said spray solution comprises at least one active agent, at least one excipient, and at least one solvent.
 2. The method of claim 1 wherein said excipient comprises synthetic polymers, polysaccharides, derivatized polysaccharides, sugars, sugar alcohols, organic acids, salts of organic acids, inorganic salts, proteins, amino acids, phospholipids, and pharmaceutically acceptable salt forms, derivatives, and mixtures thereof.
 3. The method of claim 1 wherein said excipient comprises polyvinyl pyrrolidone (PVP), polyethyleneoxide (PEO), poly(vinyl pyrrolidone-co-vinyl acetate), polymethacrylates, polyoxyethylene alkyl ethers, polyoxyethylene castor oils, polycaprolactam, polylactic acid, polyglycolic acid, poly(lactic-glycolic)acid, lipids, cellulose, pullulan, dextran, maltodextrin, hyaluronic acid, polysialic acid, chondroitin sulfate, heparin, fucoidan, pentosan polysulfate, spirulan, hydroxypropyl methyl cellulose (HPMC), hydroxypropyl cellulose (HPC), carboxymethyl ethylcellulose (CMEC), hydroxypropyl methylcellulose acetate succinate (HPMCAS), ethyl cellulose, cellulose acetate, cellulose butyrate, cellulose acetate butyrate, dextran polymer derivatives, trehalose, glucose, sucrose, raffinose, lactose, mannitol, erythritol, xylitol, polydextrose, oleic acid, citric acid, tartaric acid, edetic acid, malic acid, sodium citrate, sodium bicarbonate, albumin, gelatin, acacia, casein, caseinate, glycine, leucine, serine, alanine, isoleucine, trileucine, lecithin, phosphatidylcholine, and pharmaceutically acceptable forms, derivatives, and mixtures thereof.
 4. The method of claim 1 wherein the excipient is selected from lactose, mannitol, trehalose, sucrose, citric acid, leucine, glycine, and pharmaceutically acceptable salt forms, derivatives, and mixtures thereof.
 5. The method of claim 1, wherein the droplets are delivered into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 45°.
 6. The method of claim 1, wherein the first angle is at least 5° but less than 30° relative to the center axis.
 7. The method of claim 1, wherein the nozzle is configured to atomize a liquid into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 30°.
 8. The method of claim 1, wherein the first angle is at least 5° but less than 20° relative to the center axis.
 9. The method of claim 1, wherein the droplets are delivered into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 20°.
 10. The method of claim 1, wherein said composition is a solid amorphous dispersion of said active agent and said excipient.
 11. The method of claim 1, wherein said particles have an average diameter ranging from 0.5 μm to 500 μm.
 12. The method of claim 1, wherein said particles have an average diameter ranging from 0.5 μm to 100 μm.
 13. The method of claim 1, wherein said particles have an average diameter of less than 10 μm.
 14. The method of claim 1, wherein said particles have an average diameter of greater than 10 μm.
 15. The method of claim 1, wherein said active agent is selected from at least one drug, medicament, pharmaceutical, therapeutic agent, nutraceutical, nutrient, or other compounds.
 16. The method of claim 15, wherein said active agent is selected from a small molecule, having a molecular weight of 2000 Daltons or less.
 17. The method of claim 15, wherein said active agent is selected from proteins, antibodies, antibody fragments, peptides, oligonucleotides, vaccines, and various derivatives of such materials.
 18. The method of claim 15, wherein said active agent is a mixture of a small molecule, having a molecular weight of 2000 Daltons or less and a protein, antibodies, antibody fragments, peptides, oligonucleotides, vaccines, and various derivatives of such materials.
 19. The method of claim 15, wherein said active agent comprises two or more active agents.
 20. The method of claim 1, wherein said solvent is selected from water, methanol, ethanol, n-propanol, isopropanol, butanol, acetone, methyl ethyl ketone, methyl isobutyl ketone, ethyl acetate, propyl acetate, tetrahydrofuran, acetonitrile, methylene chloride, toluene, 1,1,1-trichloroethane, dimethyl acetamide, dimethylsulfoxide, or mixtures and combinations thereof. 